Ford Super Duty Power Window Wiring Diagram

Diagram Information and Instructions Shift Interlock Solenoid: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2852 - Check status of the oxygen sensor control before Three Way Catalytic Converter (TWC) (display field 1). Display Group 030 Explanation of 3 digit number block in display field 1 Page 3086 Body Control Module: Connector Views Central Control Module For Comfort System; Power Sunroof Control Module Control Modules - Connector Pin-out Page 2219 - Set and check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear -B- must be aligned with the bearing parting line (TDC cyl. 1). - Install bolt without collar for sliding rail -2- and tighten to 10 Nm. - Install sliding rail -2- with roller chain -1- and both sprockets -3- and -4- (note direction of travel of roller chain). Page 6023 Fuse Block: Application and ID Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A Fuel Injectors For Injection Quantity and Proper Seal, Checking Fuel Injector: Testing and Inspection Fuel Injectors For Injection Quantity and Proper Seal, Checking With Manufacturer's Scan Tool Checking Injectors For Leaks and Quantity Injected Special tools and equipment - VAG1348/3 remote control - VAG1348/32 adapter - VAG1602 calibration tester Test conditions - Check that fuel pressure is correct. See: Fuel Pressure Regulator/Testing and Inspection Test sequence - Remove fuel rail complete (fuel pipes/hoses remain connected). Refer to "Intake Manifold Lower Section, Disassembling and Assembling", Checking for leaks - Initiate output Diagnostic Test Mode (DTM). Page 3561 Display Group 4 Continuation of check when display = ambient temperature - Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module. - Note intake air temperature value in display field 4. - Spray sensor (arrow) with commercial chilling agent while observing temperature value. Temperature value must decrease. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation of check when display reads approx. -40.0 °C: Page 3531 - Measure resistance between terminals 2+3 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Continuation for all vehicles If specified values are not obtained: - Replace Clutch Vacuum Vent Valve Switch -F36-. NOTE: Note installation position of clutch vacuum vent valve switch in the upper installation bore of mounting bracket. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified values are obtained: Vehicles with 2-pin clutch vacuum vent valve switch - Connect multimeter between terminal 1 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 2-pin connector terminal 1 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 1243 Display Group 036 If the specified value is obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 5700 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Locations Parking Brake Warning Switch: Locations F9 - Parking brake warning light switch Page 5246 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 4412 Test Step 3 - 6 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module: Locations 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module location The control module is located in plenum chamber. Page 1174 - Measure resistance between terminals 2+3 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Continuation for all vehicles If specified values are not obtained: - Replace Clutch Vacuum Vent Valve Switch -F36-. NOTE: Note installation position of clutch vacuum vent valve switch in the upper installation bore of mounting bracket. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified values are obtained: Vehicles with 2-pin clutch vacuum vent valve switch - Connect multimeter between terminal 1 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 2-pin connector terminal 1 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 2784 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Page 5365 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 6436 End of spring (arrow) must lie against stop on spring seat. - Remove bolts -1- with vehicle standing on its wheels (raise vehicle until bolts are accessible). Page 5459 Wheel Speed Sensor: Locations Right Front ABS Wheel Speed Sensor G45 - Right Front ABS Wheel Speed Sensor Page 1568 - Loosen lock nut -1 - Adjust toe by turning tie rod (arrow) to left or right. Position wrench at nut (arrow) on tie rod. NOTE: Ensure tie rod boot is not twisted after adjustment has been completed. Twisted boots wear out quickly. - Tighten lock nut -1- to 50 Nm (37 ft. lbs.) and check toe again to ensure adjustment has not changed If toe adjustment has not moved more than 2' from specification, adjustment is ok. Steering lock (left/right), checking Test required only if: ^ Steering lock differentiates from center more than 2 ^ One side has contact between tire and component. ^ Turning circle left/right differs Distance between front axle components and tires (arrow) must be even at full lock (full turn left/right) If an imbalance exists make correction by turning tie rod left/right. Example: Right steering lock smaller than left. Loosen lock nuts at tie rod ends. - Turn left tie rod (unscrew tie rod end) - Turn tie rod, right side equal amount to left but in opposite direction (turns tie rod end in). - Check total toe. After adjustment total toe must be within specification. Tighten lock nuts. Page 2560 Removing - Remove engine cover. - Remove center and right insulation trays - Remove ribbed belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Ribbed Belt/Service and Repair - Pull off crankcase breather connecting hose between cylinder head cover and intake hose on cylinder head cover. Note: Press buttons on hose couplings to disconnect - Drain coolant See: Coolant/Service and Repair - Install engine support bracket 10-222A with legs 10-222A/1. - Insert securing hook of supporting device in right lifting eye of cylinder block and put engine under slight tension. - Unbolt engine side of assembly mounting from top of engine bracket -arrows-. Note: Use ladder VAS 5085 to remove securing bolts. - Lower engine on supporting device only as far as necessary to remove coolant pump. - Remove belt pulley. Counter-support belt pulley with water pump wrench VAG 1590 when doing this. Note: If engine has been removed, it is not necessary to remove belt pulley. The coolant pump securing bolts can be unscrewed through the holes in the pulley. Page 4326 - Separate connector-arrow- and remove shift lock solenoid -N110- downward. Installing - Join connector -arrow- to shift lock solenoid - Fit solenoid in locking pawl -arrow B-. - Clip shift lock solenoid -N110- into retainer -arrows A-. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. - Tighten nuts -arrows A- to 10 Nm. Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: Customer Interest Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 6094 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5519 ^ VAG 1331 Torque wrench or equivalent ^ Piston resetting tool Removing Note: If reusing brake pads, mark location and fit in same position when installing, otherwise uneven braking may occur! ^ Remove protective caps (arrows). ^ Using a screwdriver, pry brake pad retaining spring out of brake caliper housing (arrow) and remove. Page 3352 - The O2S sensor has been damaged by leaded fuel Checking basic voltage for oxygen sensor 2 - Remove protective cover (arrows) and disconnect 4-pin harness connector (brown) -1 - to oxygen sensor after Three Way Catalytic Converter (TWC) -G130-. - Connect multimeter using auxiliary cables from VW1594 to measure voltage at terminals 3 + 4 (harness connector to Motronic Engine Control Module (ECM)). - Start engine and measure basic voltage. Specified value: 0.400-0.500 V - Switch ignition off. If the specified value is not obtained: - Check oxygen sensor wiring. If the specified value is obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking oxygen sensor wiring, oxygen sensor 2 - Remove wiper arms and plenum chamber cover. Page 5225 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Page 3344 Oxygen Sensor: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Page 2068 - To slacken ribbed belt turn tensioning element in direction of arrow. - Block tensioner with mandrel T10060. - Remove ribbed belt. Ribbed Belt, Removing (all 2.8L 6-cylinder Engine With Power Steering Pump And A/C Compressor) Special tools, testers, measuring instruments and auxiliary items required - Hex bolt M8 X 50 2.8L - 2V NOTE: Engine cover on USA/CDN 2.8L - 2V is similar to European market 2.3L engine illustrated here. Page 670 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4826 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide A/C Control Head With Climatronic Control Module Remove/Install Control Module HVAC: Service and Repair A/C Control Head With Climatronic Control Module Remove/Install CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. NOTE: Climatronic Control Module -J255- and A/C Control Head -E87- are integrated into a single unit that cannot be serviced separately. Removing - Using a screwdriver with a protected tip carefully unclip control head trim at locations indicated by -arrows-. - Remove instrument panel screws -arrows-. - Pull out A/C control head. - Disconnect electrical connectors. - Remove A/C control head with control module. Installing Code control module, function 07, and then initiate Basic setting, function 04 See Climatronic, OBD. Page 1157 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Comfort System and Central Locking System, Assembly Overview Hood Sensor/Switch (For Alarm): Locations Comfort System and Central Locking System, Assembly Overview Comfort System and Central Locking System, Assembly Overview 1 - Coupling station Installation position: Lower A-pillar, covered by trim in footwell - Remove A-pillar lower trim to remove 2 - Door control module, FR For comfort system only - Integrated into window motor - Removing: Remove door trim - Remove window motor. 3 - Door lock, FR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. Page 647 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 3801 - Replace Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-: Vehicles with engine code AFP, item 8, - Vehicles with engine code BDF, item 8. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with engine code AFP - Check wire between test box socket 64 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Vehicles with engine code BDF - Check wire between test box socket 64 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Continuation for all vehicles - Also check the wire for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 6538 Air Door Actuator / Motor: Service and Repair Servo Motor For Fresh/Recirculating Air Door, Remove/Install Servo Motor For Fresh/recirculating Air Door - V154-, Removing And Installing Removing - Remove glove box. - Disconnect electrical connector -1-. - Remove screw -3-. - Swing motor -2- downward. - Disconnect motor -2- from fresh air/recirculating air flap lever. Installing - Engage flap motor -2- with fresh air/recirculating air lever. - Position fresh air/recirculated air flap lever by hand depending on position of flap motor. - Install screw -3-. Page 80 Section 2 - Radio antenna system diagnosis through radio unit Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit. All models except Touareg and Phaeton: - Select AM or FM. - Press and hold the mix button (black arrow). - Screen will appear that shows "Service Test mode" (white arrow). - Press mix button briefly. ^ Test one indicates current antenna status, i.e. ON or OFF (arrow). - Press mix button briefly again. Page 6334 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 299 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 6246 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Capacity ............................................................................................................................................... .................. 0.7 to 0.9 liter (0.74 to 0.95 quarts) Hydraulic Oil ........................................................................................................................................ ...................................... part number G 002 000 Note: Do not use ATF Page 2190 T 40001-6 - Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) T 40001-7 - Puller Claw for VW 2.0 Turbo; Accessory Arm Page 1322 If indicated voltage does not oscillate: - Remove instrument cluster: - Check wire connection from Engine Control Module (ECM) to Speedometer -G21- according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 4285 DTCS linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the reflash procedure first. CAUTION! The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc. If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming" (flashing) procedure: ^ Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to have been tuned, and that any damage caused by the tuning of the ECM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties. Page 5182 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 1363 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Page 4916 - Place screwdriver or similar under cover clip and pry off cover. - Mark installation position of parts 1, 2 and 3. NOTE: Noises while driving may result if indicated parts are not reassembled to their prior positions. - Felt tipped pen is suitable for marking. - Take rubber ring (arrow) out of groove. 1. Triple rotor joint housing 2. Triple roller star 3. Axle shaft Hold joint and remove axle shaft from vice Diagram Information and Instructions Power Seat Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4812 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2320 - Unscrew coolant pump securing bolts -1- and remove coolant pump -2 Note: To remove the coolant pump, push the engine to one side using a over if necessary. Installing Install in reverse sequence; note the following points: Moisten new O ring with coolant. - Insert coolant pump into cylinder block and tighten securing bolts to 20 Nm. - Fit pulley and tighten securing bolts to 15 Nm (11 ft lbs). - Align engine assembly mountings. Note: Torque settings for assembly mountings. - Install ribbed belt See: Drive Belts, Mounts, Brackets and Accessories/Ribbed Belt/Service and Repair - Fill with coolant See: Cooling System/Coolant/Service and Repair Page 3367 Possible causes of malfunction if oxygen sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) - The O2S sensor has been damaged by leaded fuel Checking oxygen sensor wiring for oxygen sensor 1 - Remove wiper arms and plenum chamber cover. Procedures Steering Wheel: Procedures Four spoke steering wheel, servicing 1. Steering wheel ^ Observe installation position when installing 2. Multipoint sockethead bolt ^ 50 Nm (37 ft. lbs.) ^ Equipped with locking compound ^ Can be used up to 5 times ^ Mark with center punch after each assembly 3. Torx bolt 4. Vibration damper ^ On TDI engine with automatic transmission 5. Torx bolt ^ 5 Nm (44 inch lbs.) 6. Airbag unit 7. Securing plate Page 4156 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Service and Repair Door Switch: Service and Repair Door Contact Switches, Removing And Installing Door contact switches are integrated into the individual door lock mechanisms and cannot be replaced separately. In case of door contact switch malfunction, replace complete door lock mechanism. Page 1957 T 40001-7 - Puller Claw for VW 2.0 Turbo; Accessory Arm Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Service and Repair Oil Pan: Service and Repair Oil pan, removing and installing Special tools, equipment, test and inspection devices; required accessories - VAG. 1331 torque wrench (5 - 50 Nm) - Hand drill with plastic brush inset - Silicone sealing compound D 176 404 A2 - Flat scraper Removing - Remove middle, left, and right damping pans. - Drain oil. - Unscrew oil pan. Note: The oil pan can be loosened by soft blows with a rubber hammer if necessary. - Use a flat scraper to remove sealing residue from cylinder block. - Use a rotating brush to remove sealing residue from oil pan, a hand drill with plastic brushes for example-inset (wear protective glasses). - Clean sealing surfaces so that they are free of oil and grease. Installing Note: Ensure that the sealing compound has a valid expiration date. - The oil pan must be installed within 5 minutes after applying the silicon sealing compound. Page 2655 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 3289 Information Bus: Component Tests and General Diagnostics CAN-Bus Checking Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Engine Control Module/Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. - Perform resistance measurement again between test box sockets 77 + 79: Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 4694 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Locations Superheat Switch: Locations Climatronic Components - Engine Compartment Cables, Installing and Adjusting Overview Air Door Cable: Service and Repair Cables, Installing and Adjusting Overview Cables, Installing And Adjusting NOTE: - Cable sleeve ends are color coded. - Always check cables before installing, replace binding or damaged cables. - Attach cables to remove controls first and then attach cables to levers. - All air flaps must audibly move onto end stops when turning controls. 1 - Central flap cable From air distribution rotary control to central flap - Cable sleeve marking: yellow 2 - Footwell / defroster - flap cable From air distribution rotary control to footwell/defrost flap - Cable sleeve marking: green 3 - Heating and ventilation controls 4 - Temperature flap cable From temperature rotary control to temperature flap - Cable sleeve marking: beige Page 3553 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no sensor malfunction is detected: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3- pin harness connector for open circuit according to wiring diagram. Terminal -1- + socket 108 - Terminal -2- + socket 90 - Terminal -3- + socket 82 - Wire resistance: max. 1.5 ohms - Additionally check wires for short to one another. If no malfunction is found in the wiring: - Remove sensor and check sensor wheel for secure fit, damage and run-out. NOTE: There is a larger gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If no malfunction is detected on sensor wheel: - Replace Engine Control Module (ECM). Page 5292 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 883 Discharge Air Temperature Sensor / Switch: Service and Repair Sender for outlet temperature, floor outlet -G192-, removing and installing Removing - Remove trim under the steering column. - Disconnect electrical connector from floor outlet temperature sender -G192-. - Turn temperature sender-1- 90° and take out from housing -2-. Installing Lubricate seal with oil when installing. Page 6258 CAUTION: ^ Using a crayon or marker, mark file direction of travel before removing the ribbed belt. Reinstalling a used belt in the opposite direction could damage the belt. ^ When installing the belt, make sure that it is correctly seated in the pulleys. ^ Determine part number from parts catalog ^ Checking condition 12. Ribbed belt tensioner Vehicles With Power Steering Pump In Upper Area 1. Bracket 2. Bolt ^ 25 Nm (18 ft. lbs.) 3. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 4. O-ring ^ Always replace 5. Banjo bolt ^ 30 Nm (22 ft. lbs.) 6. Pressure hose 7. Bolt ^ 22 Nm (16 ft. lbs.) 8. Belt pulley 9. Sockethead bolt ^ 25 Nm (18 ft. lbs.) Page 5354 Owner Letter Page 4123 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 1422 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Page 5012 1. Selector segment - Identification refer to Fig. 1 - After installing the circlip the selector segment must rotate freely 2. Circlip - Pry off with screwdriver - Installing refer to Fig. 2 - Always replace 3. 5th gear selector fork - Adjusting. 4. 5th gear selector jaw 5. Bolt, 25 Nm 6. 5th gear selector plate 7. Circlip 8. Washer 9. 3rd/4th gear selector plate 10. 1st/2nd gear selector plate 11. Reverse gear selector plate 12. 3rd/4th gear selector fork - With selector segments refer to Fig. 5 13. Selector segment - Identification refer to Fig. 1 - After installing the circlip the segment must rotate freely 14. Bearing 15. Bearing inner race, - Removing Fig. 3 - Pressing in Fig. 4 Service and Repair Fluid Pump: Service and Repair 4 Speed Automatic 01M ATF pump, disassembling and assembling Replacement ATF pump parts and the ATF pump are allocated according to the transmission code. 1. Piston ring - Check that it is correctly located see Fig. 1 - Installing see Fig. 2 2. Piston ring - Check that it is correctly located see Fig. 1 - Installing see Fig. 2 3. Piston ring - Check that it is correctly located see Fig. 1 - Installing see Fig. 2 4. Thrust washer 5. Piston - Sealing lips are vulcanized to the piston - Moisten sealing lips with ATF before inserting - Turn piston slightly when installing 6. Bolt, 10 Nm - Then turn 45° further 7. Stator support 8. Outer gear - Manufacturer's marking (arrow) faces stator support - If outer gear is incorrectly installed, the ATF pump may not operate freely in the installed position 9. Inner gear Page 6053 Power Distribution Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 5422 <-- Remove clamp -3- and disconnect intake air hose from mass air flow sensor <-- If applicable, remove secondary air hose -4- from air filter box -5<-- Remove screws -6- securing air filter box and remove air filter box ^ If applicable, remove and move aside secondary air relay box and harness from supporting clip ^ If applicable, disconnect electrical connector on brake fluid reservoir <-- Release ABS control module electrical connector by pulling latch upward -arrow 1<-- Pull electrical connector off ABS control module -arrow 2^ Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws ^ Lower vehicle ^ Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle ^ Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor ^ Raise vehicle ^ Close left front and left rear caliper bleed screws when brake fluid stops flowing ^ Lower vehicle ^ Do not remove brake pedal depressor from brake pedal at this time Note: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system ^ Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 2457 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 4165 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Page 5716 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 1816 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module: Service and Repair Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation Adaptation teaches the Engine Control Module (ECM) (with ignition switched on and engine not running) the throttle valve control module stop positions and a comparison graph between throttle valve potentiometer and throttle position sensor. Adapting sequence must be performed if: - The voltage supply is interrupted - The throttle valve control module is removed and installed - The throttle valve control module is replaced - If when installing another engine another throttle valve control module is installed Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - No DTCs stored in DTC memory. - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - Throttle valve must be at idle speed position Work sequence Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select data function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -6- and -0- to input display group number 60 (060) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 60 -> 1234 After pressing the -Q- button, the throttle valve position sensor is switched so that it is not supplied with voltage at the start of the test. In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in the throttle valve control module. The values that both angle sensors provide in the emergency running position are stored by the Engine Control Module (ECM). Thereafter, the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle valve to the previously learned emergency running position within a predetermined period (spring test). Then the throttle valve is closed by the throttle valve positioner, and the values, which are supplied by the angle sensors in the throttle valve control module, are stored by the Engine Control Module (ECM). If the Engine Control Module (ECM) switches the throttle valve position sensor so that it is without voltage during normal operation, it is indicated by an increased and varying idle. The engine reacts slowly to accelerator changes. - Check specified values (display fields 1-4): Page 697 Part 1 Page 5729 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair When working on the airbag system, the vehicle battery ground (GND) strap must be disconnected. No waiting time is necessary after disconnecting the battery. When connecting the airbag system to a voltage source no person can be present inside the vehicle. Steps for performing repairs on airbag system. 1. Disconnect battery ground (GRD) strap. 2. After installing/repairing of components is completed, switch on ignition. 3. Close doors. 4. Connect battery ground strap. Visual and functional check of airbag warning light system. - The warning light must light for approximately 3 seconds when the ignition is switched on. - The warning light must switch off after approximately 3 seconds and then not light again or flicker during a road test. Observe additional service precautions. See: Restraint Systems/Air Bag Systems/Service Precautions Page 199 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1000 Warranty Required Parts and Tools 4 Speed Automatic 01M, Torque Converter Seal Seals and Gaskets: Service and Repair 4 Speed Automatic 01M, Torque Converter Seal Automatic Transmission Model 01M Torque converter oil seal, removing and installing Special tools and equipment - VW 681 Extractor lever - 3158 Drift sleeve Removing torque converter oil seal Page 2383 * Call Volkswagen Tools and Equipment Program (EQS), which is Equipment Solutions for product. Part number(s) are for reference only. Always see Parts Dept. for the latest part(s) information. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 1392 Impact Sensor: Locations Right Rear Side Airbag Crash Sensor G257 - Right rear side airbag crash sensor Page 4460 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. Locations Windshield Washer Relay: Locations RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2856 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the oxygen sensor control in display field 1 does not fluctuate as stated: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values in display field 1 are not obtained even after a road test or the value does not fluctuate by at least 2 %: - Check oxygen sensor (before Three Way Catalytic Converter (TWC)) aging. Evaluating display field 32, display field 1: Oxygen sensor learned values before Three Way Catalytic Converter (TWC) Page 3662 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 4097 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Service Locations Parking Brake Warning Switch: Locations F9 - Parking brake warning light switch Power Supply and Cables Check Electronic Throttle Control Module: Testing and Inspection Power Supply and Cables Check Checking the power supply and cables to the control module - Remove driver side shelf: - Disconnect 6 pin connector for throttle position sensor. - Turn on ignition. - To measure voltage, connect multimeter to following contacts of connector: Contact 1 + ground - Contact 1 + 5 - Contact 2 + ground - Contact 2 + 3 - Specification: at least 4.5 V - Turn off ignition. If the specifications are not achieved: - Connect VAG 1598/31 test box to control module wiring. Do not connect engine control module. Page 2231 - Install cover piece, insert all mounting bolts and turn in opposite direction slightly. CAUTION: Do not damage Cylinder Head Gasket, when installing timing covers. - Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. Page 2671 Description and Operation Voltage Regulator: Description and Operation Compact Generator (GEN) 06.00 > Starting model year 2001, compact generators with a modified construction shape are used. The terminal designations are maintained. The new generators have no removable protective cap, in contrast to the previously used generators. In these generators, the Voltage regulator (VR) can no longer be replaced. If the Voltage regulator (VR) is defective, the complete generator must be replaced. Page 4994 ^ Remove transmission drain plug -1- and bearing pin -2-, allow transmission to totally drain. ^ Install bearing pin -2- using new grommet. ^ Install drain plug -1-. ^ Turn bracket -A- back to original position so the selector shaft -1- can move freely. Transmission, filling: ^ ADD new transmission oil Part No. G 055 726 A2 to oil already in catch container until total volume is 1.9L (2 qt.). ^ Remove back up light switch arrow -1-. ^ Connect a rubber hose (approx. 600 mm (24 in.) long with a 10 mm (3/8 in.) diameter) to a funnel. ^ Insert hose into hole of back up light switch and fill transmission. ^ Install back up light switch. ^ Check the operation of shifter. install air filter housing. ^ Install sound insulation. 02J Manual 5 Speed Transmission, Draining and Re-filling See Repair Manual Group 34, Manual Transmission - Controls, Housing. Recall - ABS Control Unit Replacement Technical Service Bulletin # RECALLWJ Date: 020301 Recall - ABS Control Unit Replacement Recall Circular Code: WJ Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit Dear Volkswagen Dealer: This is to inform you of the initiation of a voluntary safety recall involving some 2001 and 2002 model year Volkswagen Golf, Jetta, GTI and New Beetle vehicles. Problem Description Volkswagen has found that an electronic chip in the control unit could experience an electrical short causing the connector wire insulation to become scorched. Remedial Action Check and replace, where required, ABS control unit. Vehicle Identification Number Ranges The vehicles affected by this recall action are within the following vehicle identification number ranges: Please note that the above VINs represent the lowest and highest serial numbers of affected vehicles. Use of the OTIS campaign inquiry system will allow you to determine whether or not a particular vehicle, within the above VIN ranges, requires the corrective work. Note: Volkswagen will not reimburse under recall any duplicate recall repair work or a repair outside the VIN ranges. Owner Notification Mailing Volkswagen of America, Inc. will mail first class notification letters to all known owners of affected vehicles on or about March 14, 2002. A copy of the owner letter is enclosed for your information. Vehicle Allocation Under separate cover and prior to owner notification, we will provide you a computer printout list containing VINs including owner names and addresses of vehicles located within your dealership's area of responsibility. Note: The above listing will include names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts Information Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 6475 6500 X-32 - 32mm, 12-Pt. Socket Diagram Information and Instructions Shift Interlock Solenoid: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4102 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 564 - Reduced Transmission life. Page 5325 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 3309 Code numbers for all control modules connected to the CAN-Bus must be added. Example: Airbag + ABS + Autom. transmission: 00004 + 00002 + 00001 = 00007 - Use scan tool button pad to enter code number. Indicated on display (example only): 6N0909901 Gateway K <-> CAN 0001 Coding 00007 WSC 00000 - Press -Q- button to confirm input. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -6- to select "End Output" function 06. The tester is again in basic function. Page 4127 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Inner Constant Velocity Joint, Checking Constant Velocity Joint: Testing and Inspection Inner Constant Velocity Joint, Checking Disassemble joint to replace grease or check for wear and damage. - Swivel ball hub and ball cage. - Press out ball cage in direction of arrow. - Press balls out of cage. NOTE: Ball hub and joint are paired and must not be interchanged. - Tilt ball hub out of cage over ball track (arrows). - Check joint housing, hub, cage and balls for pitting and signs of seizure. NOTE: Excessive backlash in joint will be noticed as a knock during load changes. In such cases replace joint. Polished areas and ball track marks are not reasons to change joint. Installing: - Insert ball hub over both chamfers into ball cage. Hub can be installed in any position. Press balls into cage. - Insert hub with cage and balls at right angle to joint. Page 5833 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3709 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Specifications Compression Check: Specifications Compression pressure New 10 - 13 bar Max. wear 7.5 bar Permissible variation between cylinders 3 bar Engine Controls - MIL ON/DTC P0134 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0134 Set Group: 01 Number: 04-20 Date: Oct 27, 2004 Subject: Malfunction Indicator Light (MIL) ON with DTC P0134 Stored in DTC Memory Model(s): Golf / Jetta with 2.8L VR6-2V 1999 --> 2002 (Eng. code AFP) Condition Customer states Malfunction indicator light is ON in the instrument cluster. Concern may be accompanied by Diagnostic Trouble Code (DTC) P0134. Service - Verify customer concern. See Workflow Overview for Service Procedures incorporated into this Technical Bulletin. CAUTION! Part numbers listed in this T.B. are for reference only. Always check with your Parts Dept. for the latest parts information. Note: Procedure must also be performed on applicable vehicles in Dealer inventory. Procedure: Update - Programming (Flashing) CAUTION! When performing the reflash procedure, ALL DTCs for all systems are erased. Page 4363 Clutch: Service and Repair 1st to 3rd Gear Clutch 4 Speed Automatic 01M 1st to 3rd gear clutch -K1-, disassembling and assembling Special tools and equipment - VW 401 Thrust plate - VW 402 Thrust plate - VW 412 Press tool - VW 442 Thrust pad - 40-203/1 Tube, split Note: The clutch should only be disassembled for cleaning or to visually check parts. The clutches -K1- and -K3- are pressed together. Pressing -K1- off-K3- Pressing -K1- onto -K3- Page 5300 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3376 - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Oxygen Sensor (O2S) And Oxygen Sensor Control Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. - The oxygen sensor (before catalytic converter) has a static regulation and can be differentiated from the oxygen sensor behind catalytic converter via a 6-pin connector. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degrees C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor before catalytic converter must be OK. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor Before TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals - End diagnosis and switch ignition off. If specified values are not obtained: - Test oxygen sensor wires. Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Page 1320 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Connect multimeter to measure voltage between test box sockets -2- + -54-. - Switch ignition on. - Lift vehicle at left-front. - Rotate front wheel and observe voltage display. Specified value: between 0 and at least 4 Volts, fluctuating. NOTE: If necessary, hold the right-front wheel to prevent it from turning. If the display does not fluctuate: - Check wiring to speedometer/speedometer sensor. - Check DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 3566 Intake Air Temperature Sensor: Testing and Inspection With Generic Scan Tool Intake Air Temperature (IAT) Sensor, Checking NOTE: The Intake Air Temperature (IAT) Sensor -G42- is a component of the Mass Air Flow (MAF) Sensor -G70- and cannot be replaced individually. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram - Chilling spray (commercially available) Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 15: Intake air temperature". - Check specified value of intake air temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which is below the ambient temperature of sensor, first check sensor wires for contact resistance. Note that while the vehicle is standing still the sensor might warm up due to radiant heat. If specified value is obtained: - Remove intake air hose between Mass Air Flow (MAF) sensor and throttle valve control module: Vehicles with engine code AFP, item 3, - Vehicles with engine code BDF, item 16. - Remember the intake air temperature value. Page 867 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 3064 Intake Air Temperature Sensor: Testing and Inspection With Generic Scan Tool Intake Air Temperature (IAT) Sensor, Checking NOTE: The Intake Air Temperature (IAT) Sensor -G42- is a component of the Mass Air Flow (MAF) Sensor -G70- and cannot be replaced individually. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram - Chilling spray (commercially available) Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 15: Intake air temperature". - Check specified value of intake air temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which is below the ambient temperature of sensor, first check sensor wires for contact resistance. Note that while the vehicle is standing still the sensor might warm up due to radiant heat. If specified value is obtained: - Remove intake air hose between Mass Air Flow (MAF) sensor and throttle valve control module: Vehicles with engine code AFP, item 3, - Vehicles with engine code BDF, item 16. - Remember the intake air temperature value. Page 2628 Part 2 Page 6419 Subframe: Service and Repair Sub-Frame, Removing and Installing Sub-frame, removing and installing Special Tools and equipment 3283 Press VAG 1383 A transmission jack Removing - Remove noise insulation. - Remove bolts -1-. - Disconnect axle shaft from transmission drive flange. - Pull wheel bearing housing with ball joint out, from control arm. - Swing wheel, with suspension strut, out and support. Page 517 Page 190 Page 173 Page 4245 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide Page 307 Page 2214 - Remove outer intermediate sprocket and inner intermediate sprocket. Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 2783 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 1477 Part 1 Page 1397 Impact Sensor: Service and Repair Crash Sensor For Driver Side/Passengers Side Rear Side Curtain Protection, Removing and Installing Crash Sensor For Driver Side/Passengers Side Rear Side Curtain Protection, Removing And Installing NOTE: - Removal and installation is described for right side of vehicle. same instructions apply for removal and installation for left-hand side. - illustration shows chassis version of notchback, removal of crash sensor side rear level airbag is identical for sedan and wagon. - Observe notes regarding coding in radio operators manual before disconnecting battery. - After connecting battery, vehicle options (radio, clock, electric window regulator) must be checked according to repair manual and/or user manual. - "crash sensor for rear side-airbag" sends signal to deploy head-level and side-airbags in certain accident situations. - "crash sensor for rear side-airbag on driver /Passengers side" is listed as a replacement part under "control module for side curtain protection". Removing - Switch ignition off. - Disconnect battery Ground (GND) strap. - Remove wheel housing trim. CAUTION: Observe safety precautions for working on airbags. - Electrostatic charges may result in involuntary deployment of airbag. Therefore, mechanic must be electrostatically discharged before disconnecting ignition- and Ground (GND) wires. This is done e.g. by briefly grasping chassis or door striker. - Disconnect harness connector - 2 -. - Remove bolts - 3 - and - 4 -. Page 6385 Axle Beam: Service and Repair Hydraulic Bonded Rubber Bushings, Removing and Installing Bushings -2- cannot be pressed out or in with current shop tools. If bushing -2- is damaged, the rear axle beam must be replaced. Vibration damper -4- is only on axles equipped with Hydraulic bonded rubber bushings (axles with solid rubber bushings do not have damper). Rear axle beam is supplied as a spare part assembly (including hydraulic bonded rubber bushings). 1. Axle beam ^ Stub axle contact surfaces and threaded holes are to be free of paint and dirt 2. Hydraulic bonded rubber bushing ^ Cracks and/or oil spots in rubber are indications of wear. 3. Bolt ^ 20 Nm (15 ft. lbs.) + turn 45° further ^ Always replace 4. Vibration damper ^ Vibration damper is only on axles with Hydraulic bonded rubber bushings. Axles with solid rubber bushings do not have the damper. A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Testing and Inspection Fuel Tank Vent: Testing and Inspection Fig. 3 Checking the pressure valve - Check the valve flow: A) Orifices 1 - 1: - Flow in both directions, port 2 closed B) Orifices 2 - 1: - Flow in both directions, port 3 closed C) Orifices 1 - 2: - Flow in one direction, port 3 closed The valve will close when there is vacuum at opening 1. Page 3720 Variable Valve Timing Actuator: Testing and Inspection With Generic Scan Tool Valves For Camshaft Adjustment (Vehicles With Engine Code BDF), Checking Function The camshaft adjustment is load-and RPM dependent. The electrical valves for camshaft adjustment switch oil pressure onto camshaft adjusters (mechanical adjustment mechanisms), which then adjust the camshafts. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of the Valve -1- for camshaft adjustment -N205-and Camshaft Adjustment Valve 1 (exhaust) -N318- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P-or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Disconnect 2-pin harness connector to the respective valve for camshaft adjustment: 1 - Valve -1- for camshaft adjustment -N2052 - Camshaft Adjustment Valve 1 (exhaust) -N318NOTE: Before disconnecting harness connectors, mark allocation to component. Page 3298 Indicated on display: Rapid data transfer HELP Select function XX With Manufacturer Scan Tool Page 4939 7. Brake caliper - Servicing - Refer to Brakes and Traction Control; Servicing rear brakes (disc brakes) 8. Stub axle - Straightening operations are not allowed - Recutting the thread is not allowed! Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Lift vehicle. - Remove wheel. Page 5946 ^ Reprogram remote using VAS 5051/5052. ^ If remote remains inoperative and all diagnostic avenues have been exhausted, replace remote. Key Points to Remember ^ DO NOT attempt to reuse original battery regardless of voltage reading. A new battery must be installed. ^ DO NOT attempt to separate key portion from remote on a Touareg or Phaeton. There is a removable cover to access battery. ^ Pressing down on any button of the remote for 5 seconds, before installing the replacement battery (capacitive discharge), will erase the battery memory of the remote. If this is not done, remote will be inoperative. ^ There is no need to program remote if battery is removed for testing or replacement. However, if another problem exists, proper diagnosis needs to take place before remote is replaced. Warranty Warranty Test Center Notes: ^ 100% of remote replacements will be requested by Warranty Test Center for testing. ^ Synchronization is not considered a warrantable condition. ^ Claims that involve remote programming may be debited without proper documentation in the warranty claim. ^ Replacement battery must be included with replaced remote. ^ Any remote a technician has replaced without first performing this technical bulletin will be automatically subject to a debit. ^ Any remote that has failed due to water contamination is not considered warrantable. ^ All remotes that test NTF by Warranty Test Center may be debited. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3301 Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Engine Control Module/Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. - Perform resistance measurement again between test box sockets 77 + 79: Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Terminal Resistance For CAN-Bus, Checking Terminal Resistance For CAN-Bus, Checking Function Page 5196 - Tighten both bolts -arrows B- to 25 Nm. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Reconnect Ground strap to battery. - Check selector mechanism. - Enter radio code. Page 4583 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 3148 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 5376 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Body - Sunroof Malfunctions or is Inoperative Sunroof / Moonroof Module: All Technical Service Bulletins Body - Sunroof Malfunctions or is Inoperative 60 07 06 June 19, 2007 Page 6454 - Completely grease hole with Molykote grease. - Molykote grease, G 052 723 A2 - Use grease packet from repair kit - Install wheel bearing -1 - - press piece - 2 - install with collar in bearing) and piston cylinder - 3 with pull rod on wheel bearing housing. - Install thrust piece - 4 - with wide collar toward wheel bearing housing and special nut - 5 - on inside. - Press wheel bearing in by operating pump. - Insert circlip with needle nose pliers. 1 - Wheel bearing 2 - Thrust tube E-13-1 3 - Piston cylinder HKZ-15 4 - Thrust tube E-10 5 Special nut E-8-214 and pull rod Pressing in wheel hub - Install hub - 1 - and piston cylinder - 2 - with pull rod on wheel bearing. - Install special nut - 4 - and thrust piece - 3 - (with collar toward special nut) on inside. - Press in hub by operating the pump. 1 - Wheel hub 2 - Piston cylinder HKZ-15 3 - Thrust tube E-5 4 - Special nut E-8-214 and pull rod Further installation is in the reverse sequence to removal. Page 3128 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Page 4128 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1068 - Once seated, secure switch by turning clockwise 45°. Note: The above action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate, as well as locks in the plunger adjustment against the brake pedal. CAUTION: When installing, switch must be rotated until it is fully locked and the electrical connector is in the horizontal position. Inspect to ensure internal stop pin on retaining collar is fully seated against outer shell. - Reconnect electrical connector to switch. - Check function of brake light switch. Page 4899 Constant Velocity Joint: Testing and Inspection Outer Constant Velocity Joint, Checking Joint must be disassembled to replace grease, check for wear, and damage. Removing: - Before disassembling mark ball hub position in relation to ball cage and housing. - Swivel ball hub and ball cage. - Remove balls one after another. - Turn cage until two rectangular windows (arrow) are aligned with joint housing. - Remove (lift) cage together with hub. - Swing segment of hub into rectangular cage opening - Tilt hub out of cage. Note: Six balls of each joint belong to one tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and signs of seizure. Excessive backlash in joint will be noticed as a knock during load changes, in such cases replace joint. Polished areas and ball track marks are not reasons for changing joint. Installing: Page 3601 Continuation If the specified value is not obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the valid safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 36, display field 1 - Lambda probe voltage Lambda probe after catalyst Possible causes of malfunction if 02S sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) Page 4169 Test Step 5 - 6 4 Speed Automatic 01M Fluid Pan: Specifications Transmission Pan/Valve Body Cover 8 Nm Engine - Measurement Of Oil Consumption Engine Oil: Technical Service Bulletins Engine - Measurement Of Oil Consumption 17 11 01 March 25, 2010 2017813 Supersedes T.B. V171003 dated July 12, 2010 to include additional model year applicability and special tool purchase information. Vehicle Information Condition Oil Consumption Measurement Customer states oil consumption is higher than the Volkswagen oil consumption standard of up to 0.5 quarts per 600 miles, or 0.5 liters per 1000 km. Technical Background In order to provide effective lubrication and cooling of internal engine components, all internal combustion engines consume a certain amount of engine oil. Oil consumption varies from engine to engine and may change significantly over the life of the engine. Typically, engines with specified break-in periods consume more oil during the break-in period, and the oil consumption will stabilize after the break-in period. Refer to the Owners Manual for specific break-in procedures. Under normal conditions, the rate of oil consumption depends on the quality and viscosity of the oil, the RPM at which the engine is operated, the ambient temperature and road conditions. Further factors are the amount of oil dilution from water condensation or fuel residue and the oxidation level of the oil. Production Solution Not applicable. Service If the customer complains that their engine is apparently consuming oil in excess of the Volkswagen oil consumption standard above, an oil consumption test must be performed using the test plan in the VAS 5051 B, 5052/A, 6150 tester, before any repair is carried out. Tip Using the VAS tester, navigate to the Oil consumption measurement using one of the provided methods below: ^ GFF- Function/Component Selection: Powertrain >> Engine >> Systems capable of self diagnosis >> Motronic engine control >> Functions >> General functions» Oil consumption measurements. ^ GFF- Function/Component Selection: Drivetrain >> Engine >> Lubrication >> Sub-systems, marginal conditions >> Oil consumption measurements. 1. Follow VAS 5051B, 5052/A, 6150 test protocol exactly, and document all information on oil measurement sheets. 2. Archive the VAS 5051B, 5052/A, 6150 diagnostic log and oil measurement test sheet (attached) in the dealership vehicle service file. 3. When the customer returns the vehicle to the dealership after a minimum of 630 miles (1014 km), complete part # 2 of the oil consumption test plan Page 999 Note: Make certain the brake light switch is installed with the wiring harness connector housing pointing upward. ^ Secure the brake light switch and plunger position by slowly turning the brake light switch full to the right (clockwise) 45 degrees, and the internal stop pin of the brake light switch is fully seated at the end of slot in outer shell. Tip: A click should be heard when the switch is turned to the correct position. This action also turns the plunger shoe into the correct position to make the correct electrical contacts in the switch operate as well as locks the plunger adjustment. ^ Internal stop pin (white arrow) of the brake light switch is fully seated at the end of the slot in the outer shell (black arrow) when brake light switch is correctly installed. ^ Reconnect brake light switch wiring harness connector. If the EPC or glow plug light was blinking and there was a diagnostic code (DTC) stored in the Engine Control Module and the DTC was related to the brake light switch: ^ Connect the VAS 5051/5052 to clear DTC. ^ Create engine readiness code. ^ Depress brake pedal to verify proper function and brake light operation. ^ Install cover under dashboard. Part return pertains to U.S. vehicles ONLY ^ When requested by WTC, return all brake light switches replaced to the address below. Include a copy of the repair order, all diagnostic printouts, and any other related documentation. Volkswagen of America, Inc. Warranty Test Center 3800 Hamlin Rd. - GE01 Auburn Hills, MI 48326 Page 6344 Steering Wheel: Electrical Diagrams Diagram 46/2 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Page 1785 DO NOT exceed maximum rated capacity of refrigerant container. Leak detection Use halogen leak detector Hitec HI400A-TEL or equivalent to check for R-134a system leaks. This tool can also be used to detect leaks in R-12 systems. Many currently available R-12 leak detectors cannot detect R-134a refrigerant leaks. R-134a refrigerant oil A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems. Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2210 - Remove bolts - arrows - from upper timing chain case cover. - Remove upper timing chain case cover. CAUTION: Do not damage Cylinder Head Gasket, when removing timing covers. Page 5407 Page 5195 - Separate connector-arrow- and remove shift lock solenoid -N110- downward. Installing - Join connector -arrow- to shift lock solenoid - Fit solenoid in locking pawl -arrow B-. - Clip shift lock solenoid -N110- into retainer -arrows A-. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. - Tighten nuts -arrows A- to 10 Nm. Page 1399 - Connect battery Ground (GND) strap. Page 277 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Locations Power Protection Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 2732 Fuel Pump Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 3354 - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -0button to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -4- and -1- to input display group number 41(041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 4. Front Wheel Bearing: Service and Repair Front Wheel Bearing, Servicing II - Wheel bearing, servicing Special tools, testers and auxiliary items required ^ Thrust plate VW401 ^ Punch VW407 ^ Punch VW408A ^ Punch VW412 ^ Thrust tube VW432 ^ Thrust tube VW442 Page 3307 Display Field 1 - 4 Evaluating Display Group 126 Evaluating Display Group 126 Capacity Specifications Fluid - A/T: Capacity Specifications 4 Speed 01M Planetary gearbox fluid Capacity ......................................................................................................... ........................................................................ 5.3L (filled for life, no change) Final drive Initial filling ......................................................................................................................... .......................................................................................... 0.75L Oil change ...................................... ................................................................................................................................................ Filled for life (no change) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... .................................................... 7.0L (filled for life) Page 4188 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 634 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Page 5023 Shifter M/T: Diagrams Shift Lever Housing 5 Speed Manual 02J Separating and Assembling Boot From Gear Lever Knob 1. Gear shift knob - Screw on and off together with boot 2. Boot collar 3. Boot with frame - Remove and install together with gear shift knob - Separating from gear shift knob = Fig. 1 - Connect to gear shift knob before installing Fig. = 1 4. Clip 5. Bushing 6. Clamp - To secure gear shift knob on gear lever 7. Cover 8. Hex nut, 25 Nm 9. Floor plate 10. Retainer - For gear lever housing 11. Gasket - Between selector housing and floor Page 1409 Seat Belt Buckle Switch: Locations Right Front Seat Belt Microswitch F141 - Right front seat belt microswitch Brakes - Master Cylinder/ABS Pressure Testing Adapter Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - Master Cylinder/ABS Pressure Testing Adapter Condition Master Cylinder / ABS, Adaptor for Checking Pressure Pressure adaptor VAG 1310/26 allows the use of VAG 1310 A to check for hydraulic pressure loss at either the master cylinder or ABS control unit. Before replacing the ABS unit due to an incorrect pressure reading when performing Leak Test, check brake fluid pressure at the master cylinder and ABS unit as follows: 47 06 01 Aug. 28, 2006 2002320 Supersedes T.B. Group 47 number 01-01 dated January 4, 2001 due to updated information. Technical Background Introduction of adaptor to allow pressure testing of brake hydraulic system. Production Solution No production change required. Service Pressure Leak Test Obtain special tools: - VAG 1310/26 Pressure Adaptor - VAG 1310 A Brake Pressure Gauge Use VAG 1310/26 with VAG 1310 A to measure hydraulic brake pressure at master cylinder and ABS unit as follows: - Remove brake lines at either master cylinder port (A or B). Install VAG 1310/26 at port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". Brake fluid pressure can also be checked at the ABS unit: - Disconnect brake lines from ABS unit to disc brake calipers (1-4), one at a time. Page 6105 Fuse arrangements in fuse holder, instrument panel left Page 2374 ^ Remove passenger side sill panel trim. ^ Lift rear seat and remove cover for fuel pump/fuel gauge sensor. Engine overlay harness, preparation Prior to installing the engine overlay harness, prepare the harness as follows: ^ Locate single wire portion of engine overlay harness. ^ Cut terminal and wire approx. 5cm (2 in.) from terminal end (SAVE for reinstallation at a later point in procedure). Vehicles without Climatronic: ^ Cut ambient temperature sensor wire and tape back to harness (see above - Unused wiring, taping back to harness). ^ Locate two wire portion of engine overlay harness. ^ Locate guide tube from kit, cut one end at sharp angle. ^ Insert one wire from two wire portion of engine overlay harness into guide tube and tape second wire over guide tube using vinyl tape. Engine overlay harness, installing Page 5497 Remove piston seal using wedge 3409. Note: When removing piston seal make sure that the cylinder bore is not damaged. Installing ^ Lubricate piston, piston seal and cylinder bore lightly with assembly lubricant G 052 150 A2 ^ Install new piston seal in caliper. ^ Place protective seal with outer sealing lip on piston. ^ Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409. ^ Press piston into brake caliper housing using piston resetting tool. The protective seal outer sealing lip must slip into the piston groove. Page 5137 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Service and Repair Steering Column Lock: Service and Repair Steering lock housing, removing and installing Removing Airbag and steering column removed. Upper and lower steering column trim removed. - Remove steering column switch bolt and steering column switch. - Remove plastic cover over shear bolts. Ignition lock cable must also be disconnected on vehicles with automatic transmission. - Chisel off shear bolts with chisel. Installing Attach ignition lock cable if equipped with automatic transmission. - Install new shear bolts. - Tighten shear head bolts until head shears off. - Install steering column switch. - Adjust distance between steering column switch and steering wheel. Continue installation in reverse sequence Page 1203 Display Group 4 Evaluating display group 4, display field 4-Intake air temperature Page 583 Air Bag Control Module: Service and Repair Airbag Control Module -J234-, Removing And Installing Removing - Disconnect battery Ground (GND) strap. - Remove trim/footwell - 5 -. CAUTION: Observe safety precautions for working on airbags. - Fold bracket - 2 - opposite direction of - arrow - and disconnect connector - 3 - from control module - 1 -. - Remove nuts - 4 - (qty. 3, 6 Nm) and remove control module from studs. Installing - Installation is reverse of removal. - Switch ignition on. CAUTION: Make sure no one is in vehicle. - Connect battery Ground (GND) strap. - If control module was replaced, it must be coded, adapt (code) components. Page 5717 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Valve Spring Comp. Support - AST Tool # 2036 Valve Spring: Tools and Equipment Valve Spring Comp. Support - AST Tool # 2036 Valve Spring Comp. Support AST tool# 2036 Used in conjunction with VW 541 to install valve stem seals with cylinder head installed. May be substituted for VW 541-2. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: 3362 - Valve Spring Compressor Locations Washer Fluid Level Switch: Locations G33 - Windshield washer fluid level sensor Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5875 - Clip fuse holder mountings into battery box -1 and -2-. - Install positive terminal clamp. - Tighten securing bolt to 6 Nm. - Only after the fuse holder and positive terminal have been secured should the negative terminal clamp be installed. - Tighten securing bolt to 6 Nm. - Reinstall cover -1- with screws -arrows-. - Reinstall and secure battery cover. - Clip positive cable into retainer. CAUTION! If battery is not secured properly, the following will result: - Shortened battery service life due to vibration damage. - Battery cell and plate damage. - Electrolyte leakage due to battery case damage. - Poor collision safety. Page 6010 Page 5297 Part 1 Page 3398 Part 1 Page 6273 - Turn tightening device in direction of arrow to relieve tension on ribbed belt. For ease of illustration, relieving belt pulley tension is shown with out charge air line. - Mark ribbed belt direction of rotation. - Remove ribbed belt. - Remove hex bolt from belt pulley. Suction line and hose, removing Suction line lower spring clip can only be opened with headlight removed. Remove bumper for this. Pull connector off intake line. - Open spring clamps -1-, -2- and -3- with special tool VAS 5024. - Remove suction hose -A- and suction line. Page 2429 Page 1726 ^ Remove transmission drain plug -1- and bearing pin -2-, allow transmission to totally drain. ^ Install bearing pin -2- using new grommet. ^ Install drain plug -1-. ^ Turn bracket -A- back to original position so the selector shaft -1- can move freely. Transmission, filling: ^ ADD new transmission oil Part No. G 055 726 A2 to oil already in catch container until total volume is 1.9L (2 qt.). ^ Remove back up light switch arrow -1-. ^ Connect a rubber hose (approx. 600 mm (24 in.) long with a 10 mm (3/8 in.) diameter) to a funnel. ^ Insert hose into hole of back up light switch and fill transmission. ^ Install back up light switch. ^ Check the operation of shifter. install air filter housing. ^ Install sound insulation. 02J Manual 5 Speed Transmission, Draining and Re-filling See Repair Manual Group 34, Manual Transmission - Controls, Housing. Diagram Information and Instructions Data Link Connector, A/T: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1877 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL), Checking Malfunction Indicator Lamp (MIL), Checking Functional check - Switch ignition on. The Malfunction Indicator Lamp (MIL) must light up. If the Malfunction Indicator Lamp (MIL) does not light up with the ignition switched on: - Check MIL lamp wiring/MIL lamp bulb using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. If the Malfunction Indicator Lamp (MIL) lights up with the ignition switched on, continue check as follows: - Start engine and run at idle. The Malfunction Indicator Lamp (MIL) must go out after a few seconds. If the Malfunction Indicator Lamp (MIL) does not go out: - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. If no DTCs are stored: - Check MIL lamp wiring using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. Page 6448 Pulling bearing inner race out of hub Removing circlip Pressing wheel bearing out of wheel bearing housing Greasing hole with Molikote grease completely Molykote grease, G 052 723 A2 W/5-Speed Manual 02J/4-Speed Automatic Transmission 01M Remove Starter Motor: Service and Repair W/5-Speed Manual 02J/4-Speed Automatic Transmission 01M Remove Starter, Removing And Installing Special tools, testers, measuring instruments and auxiliary items required - VAG 1331 Torque wrench (or equivalent 5 - 50 N.m) - VAG 1332 Torque wrench (or equivalent 40 - 200 Nm) Starter (vehicles With 5-speed Manual And 4-speed Automatic Transmission 01M), Removing - Remove battery (with fastener secured fuse holder). - Remove battery (with clip secured fuse holder). Service and Repair Power Mirror Switch: Service and Repair Mirror Adjustment Switch -E43- With Mirror Selector Switch -E48-, Removing And Installing Removing - Remove front door trim. - Disconnect electrical connector. - Bend mounting frame -B- out on the longer switch side -A- and remove from mounting frame. Installing Install in reverse order of removal. Page 3879 - Check the valve flow: A) Orifices 1 - 1: - Flow in both directions, port 2 closed B) Orifices 2 - 1: - Flow in both directions, port 3 closed C) Orifices 1 - 2: - Flow in one direction, port 3 closed The valve will close when there is vacuum at opening 1. Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Component Locations Fuse: Component Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 4488 Indicated on display - Press keys 0, O, and 5 to select the Display group number 005. - Confirm entry with key Q. Indicated on display The first display zone shows the ATF temperature. - Bring ATF to test temperature. Test temperature: 35°C to 45°C - Raise vehicle. - Place container under transmission. - Remove ATF level plug from transmission oil pan. The ATF present in the overflow pipe (arrow 2) runs out. - Observe amount of ATF draining from plug hole afterward. If ATF drips out of the hole: ATF need not be topped up. Install new seal (arrow 1) to plug and tighten to 15 Nm, ATF check is completed. Page 6459 - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged (dented) dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Fastener/location Tightening torque: Brake caliper to rear axle .............................................................................................................................................................. 65 Nm (48 ft. lbs.) Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 Page 6501 - Remove brake carrier with brake caliper. To do this remove brake caliper and hang up with wire or similar. - Mark installation position of bolts from ball joint to control arm. - Remove bolts - arrows - . - Press axle shaft out. Note: When pressing axle shaft out ensure sufficient clearance is available. - Pull wheel bearing housing with ball joint out from control arm. - Remove axle shaft from wheel bearing housing and tie up. - The axle shaft must not hang down! - The inner CV joint will be damaged through overflexing. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove cover plate. - Remove connecting link from control arm. - Release speed sensor wiring from suspension strut. Caution: Place engine/transmission jack V.A.G. 1383/A underneath (danger of accident from falling parts when removing the wheel hub and the wheel bearing). Pulling out wheel hub - Insert thrust bolts -1 - in wheel bearing housing. - Install support - 2 - piston cylinder - 3 - with pull rod and special nut - 4 - . - Hold tool firmly pull out wheel hub. Page 818 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 4727 - Join connector -2- for shift lock solenoid -N110-. - Insert retainer -3- for shift lock solenoid -N110- connector in selector lever bracket. - Join printed circuit board connector-1-. - Hook locking cable into locking lever of selector mechanism. - Adjust locking cable. - Check operation of ignition key withdrawal lock. - Install central console. - Install selector lever handle. - Reconnect Ground strap to battery. - Adjust selector lever cable. - Check selector mechanism. - Enter radio code. Description and Operation Coolant Temperature Sensor / Switch HVAC: Description and Operation A/C cut-out thermal switch -F163- (Item # 9 in image) - Switches off A/C clutch -N25- at excessively high coolant temperatures. - Off at 119 °C (246 °F) - On at 112 °C (234 °F). Page 4008 - Check wiring for open circuit between test box and harness connector terminals: - Terminal 1 + socket 92 - Terminal -2- + socket 83 - Terminal -3- + socket 117 - Terminal -4- + socket 84 - Terminal -5- + socket 118 - Terminal -6- + socket 91 - Wiring resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value:Infinity ohms - Check wiring additionally for short circuit to battery positive or Ground. Specified value:Infinity ohms If no malfunction is found in the wiring: - Check Engine Control Module (ECM) voltage supply. See: Computers and Control Systems/Engine Control Module/Testing and Inspection Page 6108 S162 - Fuse -1- (30) in fuse bracket/battery S163 - Fuse -2- (30) In Fuse Bracket/Battery S163 - Fuse -2- (30) in fuse bracket/battery S164 - Fuse -3- (30) In Fuse Bracket/Battery Page 5229 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Fuel Delivery, Checking Fuel Pressure: Testing and Inspection Fuel Delivery, Checking Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. With Generic Scan Tool Checking Fuel Delivery Test requirements - Voltage supply OK - VAG1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect supply line -3- (with white marking) and catch escaping fuel using a rag. NOTE: Depress buttons on hose connections to do so. WARNING: - The fuel or fuel lines in fuel system can become very hot (danger of scalding). - In addition, the fuel system is under pressure!Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection. - Wear protective goggles and protective gloves when working on the fuel system. - Connect pressure gauge (VAG1318) to fuel supply line using adapters (VAG1318/23 and VAG1318/17). - Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. Page 4567 Test Step 5 - 6 Fuel Delivery, Checking Fuel Pressure: Testing and Inspection Fuel Delivery, Checking Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. With Generic Scan Tool Checking Fuel Delivery Test requirements - Voltage supply OK - VAG1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect supply line -3- (with white marking) and catch escaping fuel using a rag. NOTE: Depress buttons on hose connections to do so. WARNING: - The fuel or fuel lines in fuel system can become very hot (danger of scalding). - In addition, the fuel system is under pressure!Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection. - Wear protective goggles and protective gloves when working on the fuel system. - Connect pressure gauge (VAG1318) to fuel supply line using adapters (VAG1318/23 and VAG1318/17). - Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. Page 628 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 4221 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1860 - Press and hold button -1- beside the speedometer. - Turn the ignition on and release button -1- beside the speedometer. Indication -1-* or -2-** on the instrument panel (depending on the vehicles equipment) shows in reading unit -1- the warning " PROMPT SERVICE" or "service INSP" in indication unit -2-. * 1 Indicator unit in the center of the panel ** 2 Indicator unit in the speedometer - Turn adjustment button -1- beside the tachometer to the right. Page 3888 Fuel Injector: Pressure, Vacuum and Temperature Specifications NOTE: Information is not supplied by the manufacturer. Page 121 20 - Central control module - Bolted to bracket on steering column under instrument panel - To remove, remove lower steering column trim first 21 - Hood lock Contact switch for anti-theft alarm - Installation position: In lock carrier Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 1904 1 - Thrust bolt E-15 2 - Support E-40 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod 5 - High pressure hose with quick release coupling Pulling out wheel bearing - Remove circlip. - Install press piece - 1 - with shoulder to bearing, press sleeve - 2 - with four stepped internal diameters to wheel bearing housing, piston cylinder - 3 - with pull rod and special nut - 4 - . - Operate pump and remove the wheel bearing. 1 - Thrust tube E-5 2 - Press sleeve E-65-1 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod Pulling off bearing inner race from hub Pressing in wheel bearing - Clean hole from wheel bearing housing Page 3805 - To upper intake manifold, item -4- 8 - Leak detection pump (V144) Checking 9 - Air filter for leak detection pump 10 - Intake hose Make sure tight fit tight fit 11 - Mounting plate Clipped onto the charcoal canister 12 - 10 Nm 13 - Activated charcoal canister In the rear right wheel housing underneath the liner - Fastened to the body Page 1263 - Press buttons -0-, -4- and -1- to input display group number 41 (041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 2. Page 1376 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- 4 Speed 01M Transmission Drain Plug: Locations 4 Speed 01M Transmission 4 Speed 01M Transmission 1 Level Plug (with Overflow Line Tube)................................................................................................ .............................................................. 15 Nm 2 Fill Plug (with protective cap) Note: Always replace protective caps without spring retainers. The cap secures the plug. Page 166 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 4349 - Separate connector-arrow- and remove shift lock solenoid -N110- downward. Installing - Join connector -arrow- to shift lock solenoid - Fit solenoid in locking pawl -arrow B-. - Clip shift lock solenoid -N110- into retainer -arrows A-. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. - Tighten nuts -arrows A- to 10 Nm. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Service Precautions/Technician Safety Information Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Page 5665 ^ Remove trim below instrument panel. ^ Remove bolts -1-. ^ Remove cover -A-. ^ Remove connecting plate between clutch and brake pedals on vehicles with a manual transmission. ^ Remove brake light switch -1-. ^ Separate brake pedal from brake booster. ^ Guide brake booster with brake master cylinder out forward and remove. Installing Install brake booster in reverse order of removal. ^ Adjust brake light switch. ^ After installing, bleed brakes Page 1911 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Raise vehicle. - Remove wheel. - Reset brake - To do this use a screwdriver through the opening in brake drum and push adjuster upward. - Remove phillips-head screw for brake drum and take out brake drum. - Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove 12-point nut. Page 5302 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 5775 Front wheel speed sensor wiring, removing and installing Required special tools and equipment ^ VAS 1978 wiring repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery. ^ Remove Mass Air Flow (MAF) sensor connector -1- from air filter duct. ^ Remove bolts -2- at air filter -3- and place filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. - Release connector from control module (arrow -1-) and pull off (arrow -2-) Page 6349 Steering Wheel: Description and Operation General Information CAUTION! Before working on the electrical system: - Determine the correct coding for the anti-theft radio. - Switch the ignition off - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. The optional multi-function steering allows functions of the radio and cruise control to be operated from the steering wheel. The multi-function steering wheel system contains the following components: - Operating unit in steering wheel with two key pads mounted left and the right on the steering wheel with integrated electronics. - A control module for the multifunction steering wheel (located on the 13-position auxiliary relay panel). - A counterweight is installed in the steering wheel on diesel vehicles The multi-function steering wheel has On Board Diagnostic (OBD) capabilities Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the applicable standard or optional radio system and cruise control system as controlled by the multi-function steering wheel. Always read the vehicle/radio owners manual and review all radio, tape player and CD changer functions. Page 4931 Pulling bearing inner race out of hub Removing circlip Pressing wheel bearing out of wheel bearing housing Greasing hole with Molikote grease completely Molykote grease, G 052 723 A2 Page 2289 8 - 6 Nm (53 in. lb) 9 - Filter element 10 - Air cleaner lower section 11 - Air duct 12 - 10 Nm (ft lb) 13 - O-ring Always replace if damaged 14 - Intake hose Ensure seated tightly - Press together at front to release - To Secondary Air Injection (AIR) pump motor -V101-: 15 - Connecting hose For crankcase breather - From breather housing on cylinder head cover 16 - Connecting hose Note installation position - From T-piece connection on intake manifold upper section /Evaporative Emissions (EVAP) canister purge regulator valve -N8017 - Positive Crankcase Ventilation (PVC) heating element -N79- For crankcase breather 18 - To throttle valve control module -J338-* Page 3799 If the indicator does not behave as described: - Press -> button. - Start output diagnostic test mode and trigger solenoid valve 1 for charcoal filter (N80): - Check DTC memory: - Read out readiness code: - If fault memory has been erased or engine control module was separated from positive voltage supply, readiness code must be regenerated: If the specification "TEV OK" is attained: - Press -> button. - Press keys "0" and "6" for function "end output" and acknowledge with "Q." - Turn off ignition. Page 932 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 3993 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1739 Fluid - M/T: Testing and Inspection 5 Speed Manual 02J Gear oil, checking Gear oil specification. Refer to Specifications Remove insulation tray below engine/transmission, if fitted. Fill Plug Location 5 Speed Manual 02J - Remove plug (arrow) to check oil The oil level is correct when the transmission is full to the lower edge of the filler hole. - Install plug (arrow). Adding Transmission Oil - Remove plug (arrow). - Top up oil to lower edge of filler hole. - Install plug (arrow). - Start engine, engage gear and allow transmission to turn for approx. 2 minutes. - Switch off engine and remove plug (arrow). - Top up oil to lower edge of filler hole again. - Install plug (arrow). Page 6268 1. Securing bolt on starter 2. Hex bolt ^ 22 Nm (16 ft. lbs.) 3. Clamp 4. Hex nut ^ 25 Nm (18 ft. lbs.) 5. Mounting bracket 6. Pressure hose 7. Securing - bolt on transmission Page 651 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Page 2911 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (6 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (6 spd. Manual transmission) Page 3865 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 5523 Brake Pad: Service and Repair Rear Brakes Brake pads, removing and installing Special tools and workshop equipment ^ 3272 Piston resetting and removal tool ^ VAG 1331 Torque wrench or equivalent Note: If re-using brake pads, mark pad position before removing. Re-install brake pads in their original position to prevent uneven braking. Removing ^ Remove wheels. ^ Remove clip -1-. ^ Press brake lever -2- in direction of arrow and unhook brake cable -3-. Page 5375 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 6212 Adjusting toe, Refer to Alignment, Service and Repair, toe 5. Check which suspension component is installed in the vehicle. This information is found on the vehicle data sticker,Refer to Alignment Testing and Inspection, Vehicle data Sticker Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations F18 - Coolant Fan Control (FC) thermal switch Page 3898 The fuel pump must run. NOTE: This work sequence allows the fuel pump to run when the engine is not running. - Check injector for leaks (visual check). Only 1 to 2 drops per minute must emit from each valve when fuel pump is running. If the fuel loss is greater: - Switch ignition off. - Replace faulty fuel injector, item 12. Refer to "Intake Manifold Lower Section, Disassembling and Assembling", Pay attention to the following when installing the fuel injectors: - Replace O-rings on all fuel injectors and lightly moisten with clean engine oil. - Insert fuel injectors vertically and in the correct position into the fuel rail and secure using retaining clips. - Fit fuel rail with fuel injectors installed and secured onto intake manifold lower section and press in evenly. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking injected quantity - Insert fuel injector to be checked in measuring glass of tester for injected quantity VAG1602. - Connect one terminal of fuel injector to be tested to engine Ground using auxiliary cables from VW1594. - Connect second fuel injector terminal with auxiliary cable to VAG1348/3 remote control using VAG1348/3-2 adapter cable. - Connect alligator clip to battery positive (B+). - Initialize output Diagnostic Test Mode (DTM). Fuel pump must run. NOTE: This procedure allows the fuel pump to run when the engine is not running. - Operate VAG1348/3 remote control for 30 seconds. - Repeat check on other fuel injectors. To do this use new measuring glasses. - After all fuel injectors have been activated, place measuring containers on a level surface and compare quantity injected. Specified value: 110-130 ml per fuel injector If the measured values of one or more fuel injectors are above or below the prescribed specified values: - Replace faulty fuel injector, item 12. Refer to "Intake Manifold Lower Section, Disassembling and Assembling", - After all fuel injectors have been activated, place measuring glasses on horizontal surface and compare injected quantity. Specified value: 110-130 ml per fuel injector If the measured values of one or more injectors are above or below the prescribed specified values: - Switch ignition off. - Replace faulty fuel injector, item 12. Refer to "Intake Manifold Lower Section, Disassembling and Assembling", Pay attention to the following when installing the fuel injectors: Locations Brake Fluid Level Sensor/Switch: Locations F34 - Brake fluid level warning switch Page 2197 Crankshaft Gear/Sprocket: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. A/T - Leaks Near Pan Seals and Gaskets: All Technical Service Bulletins A/T - Leaks Near Pan Group: 37 Number: 00-02 Date: Dec. 22, 2000 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Condition Transmission appears to be leaking around ATF pan. In most cases the leak is NOT caused by the ATF pan gasket but by the main line pressure plug (arrow). ATF fluid flows down from the main line pressure plug to the pan seal giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace seal, Part No: N 013 811 5 - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. - Test drive vehicle and inspect transmission for signs of leakage. Page 5400 <-- Remove brake lines -3- on the side of hydraulic unit CAUTION! DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC CAUTION! MAKE SURE NO BRAKE FLUID <-- From the repair kit provided (1J0 998 375) place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates Note: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION! DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT Tools and Equipment Fuel Supply Line: Tools and Equipment Fuel Line Adapter Kit AST tool# VAG 1318-10 Fuel line adapter kit. Contents: VAG 1318-10: 12mm x 1.5 thread & 8mm hose/barb. VAG 1318-11: 8mm x 1.0 thread & 8mm hose/barb. VAG 1318-12: 12mm x 1.5 thread & 14mm x 1.5 thread. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3665 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 3124 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 1557 Alignment: Specifications Vehicle Alignment Specifications Vehicle Data Sticker Example For additional information Vehicle alignment specifications Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations F18 - Coolant Fan Control (FC) thermal switch Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 4651 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Specifications Idle Speed: Specifications Not adjustable 680 to 720 rpm Page 1700 Fluid - A/T: Fluid Type Specifications 4 Speed 01M Planetary gearbox fluid Type ............................................................................................................... .......................................................................................................... VW ATF VW Part no. ................ .............................................................................................................................................................. ........ G 052 162 A1 (0.5 liter) VW Part no. .......................................................................................... ............................................................................................ G 052 162 A2 (1.0 liter) Final drive Type ................................................................................................................................... ........................................... Gear oil SAE 75W-90 (synthetic oil) VW Part no. .................................... .................................................................................................................................................. G 052 145 A1 (0.5 liter) VW Part no. .............................................................................................................. ........................................................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Type ..................................................................................................................................................... ............................................................................ ATF VW Part no. .................................................... .................................................................................................................................................. G 052 990 A2 Locations Shift Interlock Solenoid: Locations N110 - Shift lock solenoid Page 4255 When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update programming procedure first. NOTE: Non-observance of the following points may lead to ECM failure! VAS 5051 or VAS 5052 must always be connected to the approved power supply at the approved voltages. Under no circumstances should the power supply be interrupted or the diagnostic connector unplugged during the update programming procedure. Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF. Tip: Before update programming, delete the fault memory in the ECM. Update programming is not possible when an EEPROM fault is active. Reprogram ECM with CD - Part number MY99022VVR6CAT. - Insert the programming CD into the VAS 5051 / 5052, and access the ECM. Tip: If the update programming button does not appear, the latest version has already been installed to the level below. - Programming starts by pressing the "Update Programming" button and following the on screen prompts. NOTE: Once update programming begins, on NO occasion should the Cancel button be selected. - Press the "Update Programming" button. Tip: Once update programming is complete, it is recommended to use 1001- Compiling Services prompt to clear faults stored in various control modules. - Reset readiness code. Warranty Required Parts and Tools No Special Tools required. Page 2411 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 151 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2976 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 5637 Load Compensator: Service and Repair Brake pressure regulator, mounting 1 Brake pressure regulator ^ Checking and adjusting 2 Socket head bolt, 21 Nm (15 ft. lbs.) 3 Bolt 4 Nut, 21 Nm (15 ft. lbs.) 5 Spring 6 Mounting bracket Page 4637 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5321 Owner Letter Page 4723 Selector mechanism, removing and installing - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - With ignition switched off disconnect battery Ground strap. - Remove selector lever handle. - Remove central console. - Disconnect locking cable from the selector mechanism locking lever. - Separate printed circuit board connection -1-. - Using a screwdriver, carefully pry retainer-3for shift lock solenoid connector -2- out of selector lever bracket. - Separate shift lock solenoid connector-2-. - Carefully pry off frame at four corners -arrows- and remove. - Remove front selector mechanism securing nuts (Qty. 2). - Pull selector lever cable -1- upward off lever/selector shaft -4-. - Remove circlip -3- at support bracket. Engine - Oil Drain Plug Thread Cleaning Engine Oil Drain Plug: Technical Service Bulletins Engine - Oil Drain Plug Thread Cleaning Condition 17 07 05 Mar. 2, 2007 2010621 supersedes Technical Bulletin Group 17, number 04-04 dated Dec. 3, 2004 due to additional models and inclusion in ElsaWeb. Oil Pan Drain Plug, Cleaning Threads on Plug and Oil Pan When Changing Oil Technical Background Engine oil leaks are found after engine oil is changed. This condition may be caused by contaminants on the threads of the oil drain plug or the oil pan (if both are not cleaned before installing and tightening the oil drain plug to the proper torque). Production Solution N/A Service After draining engine oil: ^ Clean any contaminants from both oil drain plug and oil pan drain hole threads. ^ Carefully inspect drain plug and oil pan threads for damage. ^ If drain plug is damaged, replace it along with drain plug seal. ^ Replace either drain plug with seal, or drain plug seal only (if available separately), as necessary. Tip: Always see ETKA for the latest part(s) information. Note: In some cases the drain plug comes with an integral (permanent) seal and must be replaced as a unit. Never install a drain plug sealing ring from another application (always consult ETKA for the appropriate drain plug / sealing washer combination). ^ Install oil drain plug and hand-tighten first. Then, using a torque wrench, tighten to the proper specification as listed in the table below. See Required Crash Sensor For Driver-Side And Passenger Side - Side Airbag, Assembly Overview Impact Sensor: Service and Repair Crash Sensor For Driver-Side And Passenger Side - Side Airbag, Assembly Overview Crash Sensor For Driver-side And Passenger Side - Side Airbag, Assembly Overview 1 - Driver-side and passenger-side sensor 2 - Connector 3 - Bolt Qty. 2, 6 Nm 4 - Carpet Page 5960 - Remove intake hose -1-, electrical connection -2- and hose -3- from Mass Air Flow (MAF) Sensor - Remove screws -4- and -5- and remove complete air filter assembly. NOTE: Starter can be removed without prior removal of battery and battery mounting. For clarity, the following illustrations show the battery removed. - Remove bracket -arrow- from transmission. - Ensure transmission selector is in "Park" and lever shifter cable end -1- from shifter lever -4using screwdriver. - Unclip shifter cable from holder -3- lift out shifter cable and set aside. CAUTION! - Do not remove screw -2-. - Do not kink shifter cable Page 3396 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2994 - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose -1- and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Continuation for all vehicles - Start engine and let run at idle. - Measure fuel pressure. Specified value: about 2.5 bar positive pressure Vehicles with engine code AFP - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Vehicles with engine code BDF - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Continuation for all vehicles Page 3183 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 3320 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Page 2093 Parts and Tools. Note: Always clean contaminants from both oil drain plug and oil pan drain hole threads. Never use air tools to install the oil drain plug, as damage to the oil pan can occur. Do not exceed the specified torque. Exceeding the specified torque may damage the oil pan or bend the sealing washer, which can lead to leaks at the drain plug. Oil pans with damaged threads will not be covered under Warranty. Engine oil, filling To prevent overfilling, for all engines: ^ Add approximately 1/2 quart (or liter) less than capacity. ^ Start engine and let run until engine operating temperature is approximately 60°C (140°F), switch ignition off. ^ Wait about three minutes. ^ Check level on oil dipstick and fill to dipstick full mark. This may be even more or less than 1/2 quart (or liter), depending on engine. Warranty Information only Required Parts and Tools No special parts required. Always see ETKA for the latest part(s) information. Page 3971 Fuel Tank Unit: Tools and Equipment Fuel Sender Spanner AST tool# 3217 Used to remove and install the fuel gauge sending unit (139mm). - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 4482 Fluid - A/T: Fluid Type Specifications 4 Speed 01M Planetary gearbox fluid Type ............................................................................................................... .......................................................................................................... VW ATF VW Part no. ................ .............................................................................................................................................................. ........ G 052 162 A1 (0.5 liter) VW Part no. .......................................................................................... ............................................................................................ G 052 162 A2 (1.0 liter) Final drive Type ................................................................................................................................... ........................................... Gear oil SAE 75W-90 (synthetic oil) VW Part no. .................................... .................................................................................................................................................. G 052 145 A1 (0.5 liter) VW Part no. .............................................................................................................. ........................................................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Type ..................................................................................................................................................... ............................................................................ ATF VW Part no. .................................................... .................................................................................................................................................. G 052 990 A2 Page 4721 - Fitted on front tunnel heat shield 8. Locking plate - Secures selector lever cable to mounting bracket - Always replace 9. Selector lever cable - Do not bend or kink - If outer cable is damaged the selector lever cable must be replaced - Checking and adjusting - Removing and installing - Do not grease cable eye and ball socket 10. Collared nut, 10 Nm. - For cover to mounting bracket - Qty. 4 - Self-locking - Always replace 11. Cover - For mounting bracket - With bonded seal 12. Hex bolt 13. Locking pawl - For selector lever lock - Grips into cable lever of mounting bracket 14. Shift lock solenoid -N110 - Can be replaced with selector mechanism installed - Removing and installing - Can be checked in electrical test and in measured value block 15. Mounting bracket - Removing and installing 16. Locking cable - For ignition key removal lock - Must not be kinked - Removing and installing - Adjusting - Checking operation of the ignition key withdrawal lock. 17. Steering lock 18. Clip - Position: push on clip from above. The angled ends of clip face steering lock. Selector Lever Handle Removing and Installing Removing and installing selector lever handle Removing Shift selector lever to position "R". Page 2693 Page 1295 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 2283 Explanation of 8 digit number block If the specified value is obtained: - Briefly increase engine speed (rev- up) and allow engine to run at idle for 2 minutes. Checking idle speed - Change to display group 056 as follows: - Press -C- button. - Press buttons -0-, -5- and -6- to input display group number 56 (056) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 56 -> 1234 - Check actual idle speed in display field 1. - Check specified idle speed in display field 2. - Check operating mode in display field 4. Explanation of 5 digit number block Page 12 - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. Fuel System - Fuel Tank Ground Strap Installation Ground Strap: Technical Service Bulletins Fuel System - Fuel Tank Ground Strap Installation 20 07 02 Feb. 27, 2007 2001950 Supersedes Technical Bulletin Group 20 number 00-02 dated March 15, 2000 due to inclusion into ElsaWeb and Metadata. Affected Vehicles Condition Replacement Fuel Tanks, Installing Grounding Strap Technical Background All replacement fuel tanks do not come with grounding strap (wire) installed. Production Solution No production change required. Service Tip: The grounding strap must be installed into all replacement fuel tanks. Install grounding strap, see Required Parts and Tools, into replacement fuel tank as follows: - Remove fuel filler cap - note cautions written on cap. - Bend up tab on inside of fuel filler pipe as shown -arrow-. Tip: Fuse Holder, Removing and Installing Fuse Block: Service and Repair Fuse Holder, Removing and Installing Fuse Holder And Relay Carrier CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Fuse Holder, Removing And Installing - Carefully pry-off side cover from instrument panel (left). - Remove driver's side instrument panel trim. - Remove screws -B- (2 Nm) and then press locking device -C- when doing this pull fuse holder -Aout inward. Page 5280 Page 4706 - Separate connector-arrow- and remove shift lock solenoid -N110- downward. Installing - Join connector -arrow- to shift lock solenoid - Fit solenoid in locking pawl -arrow B-. - Clip shift lock solenoid -N110- into retainer -arrows A-. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. - Tighten nuts -arrows A- to 10 Nm. Page 3481 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Checking voltage supply terminal 30 - Measure supply voltage between test box sockets 1 + 62 using multimeter and adapter cables from VW1594: Specified value: at least 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from battery (B+) voltage, the readiness code must be generated again. Checking voltage supply terminal 15 - Measure supply voltage between test box sockets 2 + 3 using multimeter and auxiliary cables from VW1594. - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Voltage Supply For Engine Control Module (ECM), Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 5816 ^ (3.2L) Test/charge AGM battery located in trunk - one 6V battery located on each side of ski chute, as shown. 2-4 Golf VR4/R32 2008 - 2010 Testing/Charging at Battery Tip: DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions: ^ Battery was removed for a separate repair prior to performing battery test. ^ Over the counter (after market) parts. When testing or charging battery either installed or removed from vehicle: ^ Select Standard (Lead-Acid) battery. Located in right trunk area under spare tire and tool kit. ^ Always use actual DIN rating from battery label. When testing or charging battery installed in vehicle: ^ DO NOT Test/Charge from Remote Location (3.2L). ^ (3.2L) DO NOT use remote location (+) -arrow- Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Speed Automatic 01M Shift Interlock Solenoid: Service and Repair 4 Speed Automatic 01M Shift lock solenoid -N110-, removing and installing Removing Obtain radio code on vehicles with coded radio. - Disconnect battery Ground strap. - Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7 and remove. Note contact spring for selector lever position display! - Remove locking segment (2 bolts). - Place selector lever in position "1". - Remove retaining bracket -8- (2 nuts). - Remove solenoid securing bolts -9- (Qty. 2) - Remove front selector mechanism securing nuts (Qty. 2). - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. Note: Do not bend or kink the selector lever cable. Page 2364 ^ Cut tie-wrap (arrow), remove blue flat contact housing cover and cloth tape from the overlay harness. ^ Locate the red/violet wire from position 22 (will splice to violet/red wire from coolant level sensor of engine overlay harness). ^ Locate brown/white wire from position 7 (will splice to brown/white wires of engine overlay harness and fuel pump overlay harness). ^ Once located, separate these wires from the wire cluster (when splicing wires, splice these wires first). Instrument cluster overlay harness, general instructions for wire splicing 1. Use Part No: 111971941A (Light yellow crimp connectors) for all positions except brown/white wire. 2. Use Part No: 111971940A (red crimp connector) to connect brown/white wires from engine and fuel pump overlay harnesses to brown and white wire from instrument cluster overlay harness (2 wires connect to 1 wire).) When splicing instrument cluster overlay harness you must: 1. Maintain a harness length of 40cm from the blue connector to the main harness take out point. 2. Stagger crimped connections to maintain a flexible and compact harness. 3. Not all wires in the instrument cluster overlay harness will be used on every vehicle. 4. The overlay harness connector is made to fit many models with various equipment levels. Any wires not used should be folded and taped back into the harness (see above - Unused wiring, taping back to harness). 5. Tape the overlay harness connector next to the factory connector (because wiring leading to instrument cluster may vary in coloring from vehicle to vehicle compared to the overlay harness) 6. When taped side by side, you can easily trace each wire out away from the connectors in pairs (i.e. wire from position one of the overlay harness and wire from position one of the factory harness). 7. Cut original wires from factory harness (ONE AT A TIME) and reattach to the instrument cluster overlay harness. Instrument cluster overlay harness, splicing to instrument cluster ^ Start by placing all wires from factory harness to the left of the steering column. ^ With overlay harness connector taped alongside of instrument cluster harness as shown. This will allow side by side comparison of wire splicing as follows: ^ Locate the red/violet wire from position (22) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness. ^ Cut both wires. Using a light yellow splice connector Part No: 111971941A: ^ Strip, splice and crimp the red/violet wire from position (22) of overlay harness to the violet/red wire from coolant level sensor of engine overlay harness). Page 3370 - Press buttons -0-, -4- and -1- to input display group number 41 (041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 2. Page 2753 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Fuel Delivery, Checking Fuel Pressure: Testing and Inspection Fuel Delivery, Checking Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. With Generic Scan Tool Checking Fuel Delivery Test requirements - Voltage supply OK - VAG1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect supply line -3- (with white marking) and catch escaping fuel using a rag. NOTE: Depress buttons on hose connections to do so. WARNING: - The fuel or fuel lines in fuel system can become very hot (danger of scalding). - In addition, the fuel system is under pressure!Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection. - Wear protective goggles and protective gloves when working on the fuel system. - Connect pressure gauge (VAG1318) to fuel supply line using adapters (VAG1318/23 and VAG1318/17). - Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. Page 560 Display Group 060 - Terminate engine basic setting at earliest after 30 seconds by pressing -> button. Adaptation has been performed successfully. To store the values: Page 2912 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (5 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission) Page 5569 Brake Fluid: Service and Repair Checking brake fluid level: The brake fluid reservoir is below the left side of the plenum panel. See illustration. The correct fluid level is important for the proper functioning of the brake system. The fluid level in the brake fluid reservoir should always be between the "MAX" and "MIN" markings. The fluid level may drop slightly after some time due to the automatic adjustment of the brake pads. This is no cause for alarm. STOP! If the brake fluid level falls considerably below the "MIN" mark, the brake warning light will come on. Do not continue to operate the vehicle. The complete brake system should be thoroughly checked by a VOLKSWAGEN dealer or another qualified workshop and the cause corrected. The brake warning lamp lights up to indicate a low fluid level in the reservoir. Contact a VOLKSWAGEN dealer immediately. Changing brake fluid: The brake fluid reservoir can be difficult to reach, therefore, we recommend that you have the brake fluid changed by your authorized VOLKSWAGEN dealer. Your dealer has the correct tools and know-how to do this for you. Brake fluid absorbs moisture from the air. If the water content in the brake fluid is too high, corrosion in the brake system may result after a period of time. The boiling point of the brake fluid will also decrease considerably. Therefore, the brake fluid must be changed every 2 years. Note Remember that brake fluid is harmful to the paint of your vehicle. Because of the problem of proper disposal of brake fluid along with the special tools required and the necessary expertise, we recommend that you have your brake fluid changed by your VOLKSWAGEN dealer. It is advisable to have the fluid changed during a Maintenance Service. WARNING Brake failure can result from old or inappropriate brake fluid. Observe these precautions: ^ Use only brake fluid that meets SAE specification J1703 and conforms to Federal Motor Vehicle Standard 116. Always check with your authorized Volkswagen dealer to make sure you are using the correct brake fluid. The correct type of brake fluid is also found labeled on the brake fluid reservoir. ^ The brake fluid must be new. ^ Brake fluid is poisonous. Therefore, it must be stored only in the closed original container out of reach of children. Page 5356 Volkswagen Canada, Inc. Page 2285 Idle Speed: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 3126 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 5496 3 Cap ^ Install in mounting bushing 4 Guide pin, 28 Nm (21 ft. lbs.) ^ Removing and installing 5 Mounting bushing ^ Install in brake caliper housing 6 Brake caliper housing 7 Protective seal 8 Piston ^ Before installing apply a thin coat of assembly lubricant, Part No. G 052 150 A2, to piston 9 Piston seal Front brake caliper piston, removing and installing Special tools and equipment required ^ 3409 Wedge ^ Piston resetting tool Removing ^ Force piston out of brake caliper housing using compressed air. Note: Place a piece of wood in the recess to prevent damaging the piston. Front Axle Nut: Specifications Front Vehicles with 12-point nut Tighten 12-point nut to 200 Nm (147.5 ft lb) and then loosen 1/2 turn. Turn hub 180°. Tighten 12 point nut to 50 Nm (37 ft lb) plus an additional 60° turn. Vehicles with hex bolt Tighten hex bolt to 250 Nm (184.4 ft lb) and an additional 90° turn and then loosen 1/2 turn. Turn hub 180°. Then finally tighten to 250 Nm (184.4 ft lb) plus additional 90° turn. To tighten 12-point nut/hex bolt we recommend the angle measuring wrench VAG 1756. NOTE: If an angle measuring wrench is not available, then tighten 12-point nut using following method: - Lower vehicle until the wheels touch ground. - Tighten 12-point nut to 200 Nm (148 ft lb) and then loosen 1/2 turn (180°). - Tighten 12-point nut to 50 Nm (37 ft lb). Page 930 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5861 Design of filler support on filling bottle VAS 5045 prevents overfilling of battery cells and subsequent electrolyte leaks. When max. level is reached the flow of distilled water into battery cells stops. CAUTION! - Only use distilled water to top-up batteries. This prevents electrolyte impurities which cause self-discharging. - DO NOT overfill the battery - Overfilled batteries can boil over. - Too little electrolyte reduces the service life of the battery. - Use use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. Only use genuine cell caps of the same construction if lost or damaged. All cell caps must be equipped with an O-ring seal Electrolyte level too high Special tools, testers and auxiliary items needed - Commercially available hydrometer WARNING! - Refer to Warnings and Safety Measures. - If electrolyte level is too high, electrolyte (sulfuric acid/water mixture) may leak out and damage the surrounding area, i.e.: plenum and engine compartment. Page 426 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Locations Cabin Temperature Sensor / Switch: Locations Climatronic A/C G89 - Fresh Air Intake Duct Temperature Sensor - forward of glove box, inside fresh air intake duct, between duct and kick panel Page 4042 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 3305 Display Group 125 Page 485 Electronic Throttle Control Module: Testing and Inspection Throttle Valve Control Module J338, Checking With Generic Scan Tool Throttle Valve Control Module, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of throttle valve control module. Function The throttle valve activation occurs via an electric motor (throttle drive) in the throttle valve control module. It is activated by the Engine Control Module (ECM) according to specifications of the two sensors, Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-, function of the E-gas system. Components of Throttle Valve Control Module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for throttle drive (power accelerator actuation) -G188Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Throttle valve must not be damaged or dirty. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 17: Throttle valve position (absolute)." - Check specified value of throttle valve position (absolute) at idle stop: Page 933 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1173 Clutch Switch: Testing and Inspection With Generic Scan Tool Checking Signal From Clutch Vacuum Vent Valve Switch Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Clutch Vacuum Vent Valve Switch -F36- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Remove driver-side storage compartment. - Disconnect connector from Clutch Vacuum Vent Valve Switch -F36-. Vehicles with 2-pin clutch vacuum vent valve switch - Measure resistance between terminals 1 + 2 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 4180 Test Sep 7 - 9 Page 2160 12 - Switch-over valve 13 - Activated charcoal canister In the rear right wheel housing underneath the liner - Fastened to the body 14 - Leak detection pump for fuel system (V144) On the charcoal canister 15 - Air filter for leak detection pump Page 4570 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Locations Neutral Start Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2233 - Install lower timing cover, Torque: 6 mm bolts to 10 Nm, 8 mm bolts to 25 Nm CAUTION: Do not damage Cylinder Head Gasket, when installing timing covers. - Re-install Preliminary components, see end. Preliminary Components: - Install flywheel. - Install Clutch, please refer to: Vehicle/ Transmission and Drivetrain/ Clutch/ Service and Repair/ See: Transmission and Drivetrain/Clutch/Service and Repair. - Install upper intake manifold, , please refer to: Vehicle/ Engine/ Intake Manifold/ Service and Repair/ See: Intake Manifold/Service and Repair. - Install transmission, for Automatic Transmission please refer to: Vehicle/ Transmission and Drivetrain/ Automatic Transmission/Transaxle/ Service and Repair See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair, for Manual Transmission please refer to: Vehicle/ Transmission and Drivetrain/ Manual Transmission/Transaxle/ Service and Repair See: Transmission and Drivetrain/Manual Transmission/Transaxle/Service and Repair. - Install Valve Cover, please refer to: Vehicle/ Engine/ Cylinder Head Assembly/ Valve Cover/ Service and Repair/ See: Cylinder Head Assembly/Valve Cover/Service and Repair. - Install spark plugs. - Install Ignition Coil packs. Page 5956 - Remove bolts -arrows-and remove battery carrier. When installing tighten bolts to 6 Nm. - Separate connection -1- and remove from retainer. - Disconnect electrical connection at terminal 50 connector -2-. - Remove nut from solenoid terminal 30 wire -3- and remove cable. When installing tighten nut to 13 Nm. - Remove wiring from wiring guides. - Remove wiring guides. - Remove upper hex bolt -1- (M12 x 180 mm). When installing tighten hex bolt to 65 Nm. Page 3942 - Check Fuel Pump (FP) current draw as follows: - Reconnect all disconnected fuel lines. - Connect multimeter with electrical current probe to wire of 4-pin connector (terminal 1 arrow) from wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max: 8 amperes NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 370 Control Module HVAC: Service and Repair Control Module For Fresh Air Blower -J126-, Removing Control module for fresh air blower -J126-, removing - Remove glove box. - Disconnect electrical connector -2- and remove screw -3-. - Remove -J126-. Page 4699 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3049 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 5878 - Release battery positive terminal clamp securing bolt -arrow-. - Battery insulation jacket can only be opened and removed (where applicable) after first loosening and removing battery positive terminal clamp from battery. - Remove M8 x 25 hex bolt -arrow-. - Remove battery hold-down bracket. - If present, disconnect central gas vent hose from top cover. - Carefully lift battery from engine compartment. Battery, installing Page 1540 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5281 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 5114 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 1657 Page 1223 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 5146 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Engine - Rattling Noise On Start Up (Normal Condition) Variable Valve Timing Actuator: Technical Service Bulletins Engine - Rattling Noise On Start Up (Normal Condition) Condition Camshaft Chain Tensioner(s) or Camshaft Adjuster(s), Rattle or Knocking Noise 15 06 01 Oct. 24, 2006 2012988 Technical Background The camshaft adjustment is hydraulically actuated and controlled by the engine oil pressure. If the vehicle has been sitting, with the engine turned off for a period of time, the oil accumulation inside the camshaft adjusters partially bleeds off and the oil flows back into the oil sump. To ensure an efficient camshaft adjustment after an engine cold start, the oil pressure inside the camshaft adjusters must be built up as quickly as possible. During this time a slight rattle or knocking noise may be audible. This noise is normal at engine start and will last until the oil pressure is fully reinstated. Production Solution No production change required. Service DO NOT replace the Camshaft Tensioner(s) or Camshaft Adjuster(s) for the noise concern as described above. Tip: Replacing the Camshaft Tensioner(s) or Camshaft Adjuster(s) will not eliminate this noise. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Always see ETKA for the latest part(s) information. Page 2490 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 Brake Light Switch: Customer Interest Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 94 06 07 August 1, 2006 2012628 Condition EPC/Glow Plug Light On, DTC P0571 Stored in ECM Memory and/or Lack of Brake Light Functionality Customer may state EPC/Glow Plug Light On and/or brake lights inoperative or intermittent. DTC P0571 Brake Circuit -F- Implausible Circuit stored in ECM Memory Vehicles Affected Technical Background Condition may be caused by sensitive software or improperly installed brake light switch due to imprecise repair instructions. Production Solution No production change required. Service Diagnosis If EPC light -K132- or glow plug light -K29- is ON: ^ Go to Section A. If brake lights are not operating correctly: ^ Go to Section B. Section A - EPC or Glow Plug Light ON ^ With key ON/engine OFF, depress brake pedal to verify proper brake light operation. If brake lights are not operating correctly: ^ Go to Section B. If brake lights are operating correctly: ^ Using VAS 5051/5052, check Engine Control Module (ECM) for DTC P0571. If displayed DTC is not P0571: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. If displayed DTC is P0571: ^ Print GFF log and clear DTC. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Audio System - Poor Radio Reception Technical Service Bulletin # 9105-01 Date: 050502 Audio System - Poor Radio Reception Group: 91 Number: 05-01 Date: May 2, 2005 Subject: Radio, Reception Diagnosis Model(s): All with Premium V and VI Radio 1998 > 2006 Condition Poor radio reception. Service Procedure For concerns of poor radio reception: - Use the following as a guide for trouble shooting. Tip: This Technical Bulletin is divided into four sections: ^ Section 1: Includes antenna systems by vehicle. ^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics. ^ Section 3: Includes antenna lead diagnosis. ^ Section 4: Antenna cables Tip: ^ Perceived reception issues may be a result of environmental factors. ^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses. ^ Aftermarket window tint may interfere with reception. ^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal). Section 1 - Antenna systems by vehicle Tip: For more detail see Repair Manual Group 91- Communication of the vehicle you are working on. Passat (W8 only) Page 292 Volkswagen Canada, Inc. Component Locations Fuse: Component Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 1150 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Page 2821 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Page 4815 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 641 Test Step 3 - 6 Page 5087 Control Module: Locations J217 - Transmission Control Module (TCM) Page 2901 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 3610 Terminal 3 + socket 68 Terminal 4 + socket 69 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 5590 <-- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Note: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole <-- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket ^ Remove hydraulic unit with control module from bracket and place on a clean level work bench ^ Remove the new ABS control module (1C0 907 379 J) from package <-- Insert new adaptor -3- from kit into new ABS control module <-- Push adaptor down until clips -4- snap into position CAUTION! THE ADAPTER CAN ONLY BE PRESSED BE REMOVED AGAIN WITHOUT PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Tools and Equipment Timing Belt: Tools and Equipment Timing Belt Spanner Wrench AST tool# H 2587-2 Used for adjusting the timing belt tension and is comparable to VW tool# T10020. Applicable: 1999 and later VW Golf, Jetta, Passat, and 1999-2003 VW Beetle with 2.0L gas engine and 1.9L T.D.I. diesel engine. - Used for Adjusting the Timing Belt Tension - Applicable to 1999 and later VW Golf, Jetta, Passat, and 1999-2003 VW Beetle with 2.0L Gas Engine and 1.9L T.D.I. Diesel Engine - 2.0L Turbo (BPY) Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Page 3449 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required EPC Warning Lamp Operation Malfunction Indicator Lamp: Testing and Inspection EPC Warning Lamp Operation Electronic Power Control (EPC) Warning Lamp (malfunction Indicator Lamp For Electronic Accelerator (E-Gas)) In Instrument Cluster, Significance Location of EPC warning lamp Functional check: - Switch ignition on. The EPC warning lamp must light up. If the EPC warning lamp does not light up with the ignition switched on: - Check EPC lamp wiring/EPC lamp bulb using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. If the EPC warning lamp lights up with the ignition switched on, continue check as follows: - Start engine and run at idle. The EPC warning lamp must go out after a few seconds. If the EPC warning lamp does not go out: - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. If no DTCs are stored: - Check EPC lamp wiring using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. Page 5821 ^ Use "mV" scale on meter ^ Measure voltage drop across fuse by placing the positive lead on one side of the fuse and negative lead on other side. Page 545 Engine Control Module: Locations Engine Control Module Engine Control Module location The control module is located in plenum chamber. Page 6114 Fuse arrangements in fuse bracket/battery Page 5145 Service and Repair Valve Cover: Service and Repair Cylinder head cover, removing and installing Special tools, equipment, test and inspection devices; required accessories T1 0029 Spark plug connector tool - VAG 1331 Torque wrench (5-50 Nm) or equivalent - VAG 1921 Hose clip pliers Removing Note: The ground strap must be disconnected for this procedure. Check to see if a coded radio is installed. If that is the case, you must first obtain the anti-theft code. - With ignition off, disconnect battery ground strap. - During installation you must reinstall at same locations all tie straps that were loosened or cut during removal. - Remove spark plug connector with installation tool T10029 and unclip ignition lines. - Remove engine cover. - Disconnect connector from heating resistor (N79). - Remove inlet hose between air flow sensor (G70) and throttle control unit (J338). Page 2721 Engine Control Module: Tools and Equipment Wire Terminal Extractor AST tool# H 4673-9 Page 780 Wheel Speed Sensor: Locations Right Front ABS Wheel Speed Sensor G45 - Right Front ABS Wheel Speed Sensor Page 4189 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Page 5470 ^ VAS 1978 Wiring harness repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery ^ Disconnect wheel speed sensor wiring connector. ^ Remove rear interior side Panel trim. ^ Strip insulation (arrow) from shrink connection. ^ Cut speed sensor wiring in front of spliced connection with stripping pliers from VAS 1978 wiring repair kit and remove faulty wiring. ^ Strip insulation at wiring end by 15 mm (5/8 inch) using stripping pliers from repair kit and fold over stripped wire portion. ^ install new speed sensor wiring. ^ Connect wheel speed sensor to speed sensor wiring. Page 5298 Part 2 Page 1615 - Disconnect 5-pin connector from ignition coil (N152). - Disconnect fuse no. 32 from fuse block. Note: By removing fuse 32, the voltage feed to the injector valves is interrupted. - Completely depress accelerator pedal for wide open throttle. - Check compression pressure with compression pressure tester VAG 1763. - Crank engine until tester no longer shows an increase in pressure. Compression pressure readings: New: 10 - 13 bar Max. wear: 7.5 bar Permissible variation between all cylinders: 3 bar Page 3567 - Spray the sensor (arrow) with commercially available chilling spray and watch the temperature value. The temperature should decrease. - End diagnosis and switch ignition off. If the intake air temperature does not drop: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Continuation of test if indication is approx. -40 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Bridge terminals 1 + 3 of connector using the respective adapter cables while observing the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 98 If no apparent connection problems: - Replace amplifier. If concern is poor FM reception: - Disconnect all amplifiers, tune radio to high-powered station for your area. - Connect amplifiers one at a time. If reception is indicated: - Disconnect that amplifier and move on to next amplifier. If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues: - Replace that amplifier and check again. If there is no reception change when disconnecting and reconnecting all amplifiers: - Replace diversity/antenna selection box. Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast) - Check connections at antenna base. - Check for corrosion at mounting. If corrosion is found: - Clean mount and apply anti-seize gel to mounting. If concern is no AM and/or little or poor AM/FM reception, - Replace antenna base. Section 4- Antenna cables If antenna cables are required: - Antenna cables - single DIN (Premium V) radio. Page 1354 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 836 Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) Switch F194 - Clutch Pedal Position (CPP) Switch - above clutch pedal - above clutch vacuum vent valve -F36- Page 5116 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Page 3302 The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm If specified value is obtained (wires have no shorts): - Eliminate error in wires (see wiring diagram). End Output (Function 06) End Output (function 06) - Press buttons -0- and -6- to select "End Output" function 06. Indicated on display: Rapid data transfer Q 06 - End Output - Press -Q- button to confirm input. Indicated on display: Rapid data transfer HELP Enter address word XX - Switch off ignition. - Disconnect VAG 1551 from Data Link Connector (DLC). Reading Read Measuring Value Block (function 08) Page 5262 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. Page 5324 Page 150 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3466 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Center Air Outlet, Removing Air Register: Service and Repair Center Air Outlet, Removing Center air outlet, removing - First remove all switches located in center air outlet trim CAUTION! - Be careful not to damage instrument panel when removing switches. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. - Carefully push trim panel upwards -arrow 1- in order to disengage lower mounting clips. While doing so, pull lower portion of trim out from instrument panel -2-. - Slide screwdriver into center of air outlet outlet and disengage upper mounting retainers. - Pull out air outlet. - Remove glove box - Disconnect electrical connection for air outlet illumination. Page 369 Control Module HVAC: Service and Repair Blower Motor Speed Control CAUTION! Before working on the electrical system: - Get radio anti-theft code. - Disconnect battery Ground (GND) strap. NOTES: - After reconnecting battery: Reactivate vehicle equipment such as radio, clock and power windows. - Activate readiness code Control Module For Fresh Air Blower -J126-, Removing - Remove glove box. - Disconnect electrical connector -2- and remove screw -3-. - Remove -J126-. Page 578 Fuel Pump Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 36 - Antenna Selection Control Module -J515- (Diversity box) -3-: ^ Location Wagon; behind left luggage compartment side trim, below rear side window. ^ Location, Sedan: under rear parcel shelf. Antennas: All models use four antennas -1-, -8-. ^ Location Wagon: Integrated with rear side windows. ^ Location Sedan: Integrated with rear window. Antenna amplifiers: All models use four antenna amplifiers -2-. ^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows. ^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim. Touareg Page 63 If no apparent connection problems: - Replace amplifier. If concern is poor FM reception: - Disconnect all amplifiers, tune radio to high-powered station for your area. - Connect amplifiers one at a time. If reception is indicated: - Disconnect that amplifier and move on to next amplifier. If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues: - Replace that amplifier and check again. If there is no reception change when disconnecting and reconnecting all amplifiers: - Replace diversity/antenna selection box. Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast) - Check connections at antenna base. - Check for corrosion at mounting. If corrosion is found: - Clean mount and apply anti-seize gel to mounting. If concern is no AM and/or little or poor AM/FM reception, - Replace antenna base. Section 4- Antenna cables If antenna cables are required: - Antenna cables - single DIN (Premium V) radio. Page 1885 A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Locations A/C Pressure Switch F129 F129 A/C Pressure Switch - engine compartment, right rear ATF Level Checking and Topping Up Final Drive Fluid: Testing and Inspection ATF Level Checking and Topping Up 4 Speed Automatic 01M ATF Level Checking and Topping Up Special Tools and Equipment - VAG 1551 Scan Tool. - VAG 1551/3 Cable. - VAG 1924 Reservoir. - VW ATF is obtainable as a spare part: ‹› Container size 0.5 ltr. (0.53 qt) - Part No. G 052 162 A1. ‹› Container size 1.0 ltr. (1.0567 qt) Part No. G 052 162 A2. Page 1524 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5823 ^ Take absolute value of reading of voltage drop (ignore negative signs) and then reference voltage drop chart to determine how much current the circuit is currently consuming. See Identifying Current Consumption with Matrix attachment. ^ Check all fuses until fuse with approximate excessive current draw is identified Identification of component: 1. Once fused circuit is identified, use service repair and wiring diagram information in ElsaWeb to identify all components on circuit Page 3198 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) Switch - above clutch pedal - above clutch vacuum vent valve -F36- Page 24 Select function XX NOTE: The next time the ignition is switched "on" the identification of the engine control module is read by the immobilizer control module and stored. Page 4944 - Pull off wheel bearing/wheel hub unit from stub axle. A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Note: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 . Trunk Release Button Power Trunk / Liftgate Lock Switch: Service and Repair Trunk Release Button Removing - Remove rear lid trim. - Unclip harness connectors -1- and -2- from retainers and disconnect harness connectors. - Unclip operating rod (arrow) at lock cylinder. - Remove lock cylinder securing bolts -1- and remove lock cylinder upward. - Remove securing bolts for trunk release button (arrows) and remove button upward. Installing Installation is in reverse order of removal. Page 6432 Spring, removing and installing - Compress coil spring with-VAG 1752/1- until upper spring plate is free. - Remove nut from piston rod. - Remove individual parts of suspension strut and coil spring with-VAG 1752/1-. 1. Commercially available ratchet handle 2. T 10001/8 3. T 10001/11 4. T 10001/5 5. VAG 1752/1 Spring compressor 6. VAG 1752/4 Retainer Special tool -3186- is an alternative for tools described above. - Ensure coil spring is seated correctly in adapter-VAG 1752/4 (arrow). Installing Page 4015 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 59 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -4-. ^ Location: Above rear glass under headliner. Antennas All models use four antennas. ^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-. - Jetta / Golf / Passat (non W8) - Antenna system ^ All models use External amplified antenna mast -1-. 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 2489 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2993 - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Vehicles with engine code BDF - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. Page 871 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5256 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 4907 1. 2 Self-locking 12-point nut - Tightening - Any paint residue and/or corrosion on thread of outer joint must be removed before nut is installed. CAUTION: The vehicle must be standing on its wheels when loosening or tightening the 12-point nut. Otherwise there is a risk of an accident. 3. Axle shaft, right and left (tube shaft) - Left axle shaft is shorter! 4. Bolt - Always replace - M8 x48: 20 Nm (15 ft. lbs.) + 90° - M10x52: 50 Nm (37 ft. lbs.) + 45° - The initial tightening torque of the bolts M8 and M10 must be carried out in two steps. First apply a torque of 10 Nm and then the corresponding torque. 5. Plate 6. Hose clip - Tightening see Fig. 9 - Always replace 7. Protective boot for inner CV joint - Material: Hytrel (Polyelastomer) - No vent hole - Check for tears and chafing - Drive off CV joint using drift - Before installing on CV joint, coat sealing surface with D 454 300 A2. 8. Protective boot for inner CV joint - Material: Rubber - With vent hole - Check for tears and chafing Page 3577 System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Locations Yaw Rate Sensor: Locations G200 - Sensor for transverse acceleration (vehicles with ESP) Page 2846 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 4-pin harness connector -1- to Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130-. Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -1- and -2(harness connector to Engine Control Module (ECM)). - Start engine and run at idle - Measure voltage supply and observe display group 41, display field 4. Display: Htg.aC.ON - Specified value: 11.0-14.5 V Display: Htg.aC.ON/Htg.aC.OFF (alternating) - Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 2428 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Relay Locations Compiled From Every Wiring Section 1998-2004 Fuel Pump Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Locations Air Injection Pump Relay: Locations Component Location Component View Page 3814 - Fuse no. 43 must be OK. - The battery voltage must be at least 11.5V Test sequence - Remove fender liner rear right: - Disconnect 3-way plug of leak detection pump (V144) -arrow-. - Connect VAG 1527 B adapter cable between contact 3 (Plus) of plug and ground. - Start engine an let it run at idle. The LED should be ON. - Turn off ignition. If the LED does not light: Page 1818 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 4006 NOTES: - The display in display field 1 rises and the display in display field 2 falls because the potentiometers (angle sensors) in the throttle valve control modules run in opposite directions. - This means that the voltage of one angle sensor moves toward 5 volts (the more the throttle valve is opened the higher the voltage; percentage increases), while the voltage of angle sensor 2 drops from 5 volts toward 0 volts (the more the throttle valve is opened the lower the voltage; percentage falls). If the specified values are obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Measure resistance from throttle valve drive between terminals -3- and -5- Specified value: 1.0-5.0 ohms If the specified value is not obtained: - Replace throttle valve control module -J338- See "Intake Manifold Upper Section, Disassembling and Assembling", item 10. See: Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. See: Computers and Control Systems/Testing and Inspection - Adapt Engine Control Module (ECM) to throttle valve control module. See: Computers and Control Systems/Engine Control Module/Testing and Inspection - Display readiness code. See: Computers and Control Systems/Testing and Inspection If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Computers and Control Systems/Testing and Inspection If the specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control unit See below. - Check accelerator pedal sensor. If the voltage supply and wiring is OK: - Replace Engine Control Module (ECM). See: Computers and Control Systems/Engine Control Module/Service and Repair Checking voltage supply and wiring to control module Page 6062 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Electrical / Mechanical Repair Alternator Pulley: Electrical / Mechanical Repair Special tools and equipment - VAG1332 torque wrench (40 - 200 Nm) - 3310 socket Page 3642 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 4933 Special tools, testers and auxiliary items required ^ Thrust pad 40 - 105 ^ Press tool 3283 ^ Collar for wheel bearing inner race 3423 ^ Engine and transmission jack V A.G 1333 A with universal transmission mount V.A.G. 1359/2 ^ - 2 - Puller Kukko 18/0 Special tools, testers and auxiliary items required ^ Foot pump with high pressure hose V.A.G. 1389A/1 If there is a hand pump V.A.G. 1389/1 available in the dealership it can be converted to a foot pump. To do this use the conversion kit V.A.G. 1389/4. Service and Repair Heater Core: Service and Repair Heating And Ventilation Unit, Assembly 1 - Heater core Always replace coolant after removal/replacement - Replacing: Remove instrument panel. - Loosen instrument panel cross member. - Carefully pinch off both coolant hoses to heater core and disconnect hoses. - Seal off heater core to prevent coolant from running out CAUTION! - The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs. - Partially remove heating and ventilation unit. - Press retainer clips and remove heater core. 2 - Self tapping screw Use if retainer clips break 3 - Air distribution housing 4 - Servo motor for - fresh/recirculating air door -V154- Page 3123 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 4362 Fig. 1 Removing and installing circlip (arrow) - Press spring supporting plate down with 3267 just enough to be able to remove and install circlip. Note: Do not damage clutch housing ball valve. Fig. 2 Installation position of spring supporting plate, checking circlip Circlip (arrow) must be seated in the groove of clutch housing. Spring supporting plate must be centered relative to hub. Page 4679 Shift Interlock Cable: Adjustments 5 Speed Automatic 09A, Locking Cable, Adjusting Locking cable, adjusting CAUTION: The description below for the adjustment of the locking cable must be strictly adhered to. Adjustment prerequisites: Locking cable correctly fitted - Center console removed - Selector lever in position "P" - Ignition key in removal position Adjustment sequence: Steering wheel is in rear/lower position. - Unscrew bolt from support bracket. - Position locking cable adjustment gauge 3352 A between locking lever -1- and locking cable eye -2-. - To take up play, pull support bracket onto stop in direction of arrow. - Locking cable adjustment gauge 3352 A must be easy to remove and insert in this position. - Tighten bolt on support bracket (10 Nm). - Remove adjustment gauge. - Check operation of ignition key withdrawal lock. Page 3999 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 2808 See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 26 Terminal 3 + socket 27 Wire resistance: max: 1.5 Ohm Page 5995 Fuse: Fuse and Fusible Link Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 938 With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 3915 27 - 4-Pin Harness Connector. - Black. - For oxygen sensor behind Three Way Catalytic Converter (TWC) -G130- and heater for Oxygen Sensor (O2S) Heater 1 - Z29 -. - Located at right on underside of vehicle. - Terminals 3 and 4 plated. 28 - Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) - G130 -. 50 Nm. - Location: in rear of Three Way Catalytic Converter (TWC). - Grease only threads with G 052 112 A3 hot bolt past (anti-seize compound). Grease must not get into slots on sensor body. - Remove and install using 3337. - Oxygen sensor heater voltage supply via Fuel Pump (FP) relay - J17 -. - Check. Page 4836 Fig. 6 Identification of valve body Code letters are stamped on a metal tab. Metal tab must remain on valve body. Allocation of valve body/transmission Fig. 7 Hooking operating rod onto manual selector valve - Turn manual selector valve -1- so shoulder is to operating rod. - Guide operating rod -2- with manual selector into valve body. Fig. 8 Adjusting operating rod for manual selector valve - Move selector shaft to position "P". - Push operating rod with manual selector valve into valve body as far as stop (direction of arrow) and tighten bolt to 4 Nm. Note: The manual selector valve must always be resting against the stop. Counter-hold in the direction of the arrow when tightening the bolt - Always replace the bolt and the manual selector valve retaining clip. Page 2952 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Page 5106 Test Sep 7 - 9 A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 2016 Harmonic Balancer - Crankshaft Pulley: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 5876 Battery: Service and Repair Battery (With Fastener Secured Fuse Holder) Battery (with Fastener Secured Fuse Holder), Removing And Installing CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Special tools, testers and auxiliary items needed - VAG 1331 Torque wrench (or equivalent 5 - 50 N.m) Battery, removing First remove fuse holder on top of battery: - Switch off ignition. CAUTION! Do not loosen or remove ground strap from body. Disconnect from battery only. - Disconnect battery Ground (GND) strap from battery negative post. - Press locking lugs together -arrows- and remove cover. Page 1451 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2802 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Bridge harness connector terminals -1- + - 3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor - G70-, item -4-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display reads approx. 140 °C: Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Specifications Compression Check: Specifications Compression pressure New 10 - 13 bar Max. wear 7.5 bar Permissible variation between cylinders 3 bar Page 1316 Vehicle Speed Sensor: Locations Vehicle Speed Sensor (VSS) G68 - Vehicle Speed Sensor (VSS) With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 4083 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Page 16 - Switch on ignition. - Switch on printer with the PRINT button (indicator lamp in button lights up). - Press button -1- to select operating mode 1, "Rapid data transfer". Indicated on display Rapid data transfer HELP Input address word XX - Press buttons -1- and -7- to input address word 17 "Instrument Cluster". - Press -Q- button to confirm input. Indicated on display (example only) 1J0919860D A4 COMBI INSTR. VDO V04 -> Coding 00042 WSC 00000 - Press -> button. Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Indicated on display Rapid data transfer HELP Select function XX Immobilizer identification number (14 characters, VW...) - Press -> button. NOTE: - If this message appears in the display: Control module does not answer! HELP - Press HELP button to print out a list of possible malfunction causes. - After rectifying malfunctions, re-enter address word 17 for Instrument cluster and press -Q- button to confirm input. Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display (select functions): Rapid data transfer HELP Select function XX List of available functions Page 5546 Required Parts and Tools No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 788 ^ Using extractor tool from wiring harness repair set VAS 1978, push out applicable terminals. ^ Disconnect wheel speed sensor wiring connector. ^ Replace faulty wheel speed sensor wiring. ^ Connect speed sensor to speed sensor wiring. ^ Secure speed sensor wiring (arrows). Note: Make sure the wiring is not twisted in the wheel well. ^ Install pin connectors in connector housing. ^ Using installation tool from VAS 1978, push individual wire seals to stop. ^ Secure terminals by engaging purple latch and install cover of multi-pin connector. Page 5362 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 2218 Page 973 ^ Start engine. ^ Slowly depress brake pedal 15 times. ^ Recheck ECM for DTC. If DTC (P0571) is found: ^ Install new brake light switch. See Installation Procedure below. If no DTC is found: ^ Return the vehicle to customer. Section B - Brake Lights not Operating Correctly If vehicle brake lights do not come on or are constantly on: ^ Using VAS 5051/5052, go to Engine Electronics. ^ Read display value of measuring block 66. Display value should be XX00 with no pedal engagement. ^ Depress brake pedal and display value should change to XX11. If the last 2 digits of either display value are not correct: ^ Install new brake light switch. See Installation Procedure below. ^ If the last 2 digits of both display values are correct: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. Verify the wiring, connectors, grounds, etc. leading to the brake lights. See Repair Manual for appropriate wiring diagrams. Installation Procedure ^ Switch ignition to the OFF position and remove ignition key. ^ Remove the lower dash cover fasteners -1-. ^ Pull cover -2- out of rear holding clips and set cover aside. Page 3877 - Valve tipped 45° : closed 9 - O-Ring Always replace 10 - Switch-over valve Remove by clipping valve sideways out of its fitting - Remove cap -1- before installing - Checking See Fig. 2 11 - Vent line Black - Make sure tight fit - To activated carbon canister, item -2- Press release buttons on connecting piece to remove from flange 12 - Pressure valve For fuel tank ventilation - Check See Fig. 3 - Clip onto fuel tank 13 - Vent line Black - Make sure tight fit - Fasten with spring band clips - Clip onto fuel tank 14 - Fuel tank Hold with VAG 1383 A engine/transmission hoist when removing - Removing and installing 15 - Clamping disk 16 - Heat shield For fuel tank 17 - 25 Nm 18 - Clamping nut, 2 Nm 19 - Fuel tank cover 20 - Tightening strap Watch for different lengths - Install position: the fastening (boring) points in the direction of travel 21 - Feed line Black - Make sure tight fit - Press release tabs on connecting piece to remove from flange - To fuel rail: 22 - Fuel filter Install position: arrow shows the direction of flow 23 - Screw clamp 24 - Vent line White - Make sure tight fit - Clip onto fuel tank - To solenoid valve 1 for charcoal canister -N8025 - Sealing ring Replace if damaged - Moisten with fuel for assembly 26 - Fuel delivery module Note install position on the fuel tank See Fig. 1 - Removing and installing - Checking fuel pump - Clean strainer if contaminated 27 - Union nut Removing and installing with wrench 3217 28 - Feed line Black - Clip onto fuel tank - Press release tabs on connecting piece to remove from flange 29 - Return line Blue or blue marking - Clip onto fuel tank - Make sure tight fit - Press release tabs on connecting piece to remove from flange - From fuel rail: Page 872 Page 470 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3600 Display Group 036 If the specified value is obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 1791 Refrigerant Oil: Description and Operation Refrigerant oil A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems. See safety measures, See Warnings and Cautions regarding proper oil usage. Airborne properties Escaped refrigerant gases are heavier than air and will gather first in low places, like under the car. R-134a refrigerant gas displaces oxygen and may cause suffocation in low areas of poor air circulation. Refrigerant R-134a is not poisonous in any state (liquid or gas) and is safe when used properly. Affects on plastic Refrigerant R-134a will deteriorate some plastics. Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant. Affects on metal In its pure state, refrigerant R-134a is chemically stable and will not attack iron, copper, brass or aluminum. However, the mixture of R-134a and PAG oil may deteriorate certain metals (copper). Therefore, when making system repairs, use only genuine VW replacement parts which are specified for use with R-134a refrigerant. Water solubility Liquid R-134a refrigerant will absorb only very minute quantities of moisture. However, R-134a vapor can absorb large amounts of moisture. Flammability R-134a refrigerant is not flammable. Refrigerant containers DO NOT exceed maximum rated capacity of refrigerant container. Leak detection Use halogen leak detector Hitec HI400A-TEL or equivalent to check for R-134a system leaks. This tool can also be used to detect leaks in R-12 systems. Many currently available R-12 leak detectors cannot detect R-134a refrigerant leaks. R-134a refrigerant oil A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 system Page 3631 - Check resistance for sensor heater at connector to oxygen sensor terminal 3 + 4. - Specified value: 2.5...10.0 Ohm (at room temperature) If specified value is not obtained: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7. - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 4 + socket 5 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 6-pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Locations Steering Mounted Controls Communication Module: Locations J453 - Control module for multi-function steering wheel Page 2839 If the specified value is obtained: - Change to display group 36 as follows: - Press -C- button. - Press buttons -0-, -3- and -6- to input display group number 36 (036) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 36 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by Engine Control Module (ECM). - Check oxygen sensor voltage in display field 1. - Allow engine to run at an increased speed until specified value "B1-P2 OK" appears in display field 4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 2513 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation High Pressure Sensor G65 High Pressure Sensor G65 Where applicable, High Pressure Sensor G65 transmits a square wave signal to Coolant Fan Control (FC) Control Module J293 at a rate which varies according to the refrigerant system pressure. J293 reacts to the pulse rate of the signal from G65 as follows: If the refrigerant system pressure rises, J293 switches the radiator fan(s) to the second speed. - Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), Coolant Fan Control (FC) Control Module J293 switches the A/C Clutch N25. - On Climatronic equipped models it informs the A/C Display Control Head E87 that the pressure in the refrigerant system is OK and that A/C Clutch N25 can be switched on via J293). On applicable engines, the signal generated by G65 is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance. Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Page 1222 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 3048 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Description and Operation Ultrasonic Sensor: Description and Operation Interior Monitoring System, Description The interior monitoring system is an integral part of the anti-theft alarm system. The systems consists of two sensors into which the function of the rear reading lights are integrated. Setting the operating mode of the reading lights is performed on each of the sensors separately. The interior sensors work on the ultrasonic wave principle. The alarm of the anti-theft alarm system will be triggered if movement is detected in the interior when the system is active. The interior sensors can be switched off via a switch in the B pillar/door sill and via the adaptation (function 10, channel number 05). To do this the ignition key must be withdrawn from the ignition switch, then operate switch and lock the vehicle. The sensors will be switched on again the next time the vehicle is unlocked. A waiting time of at least 30 seconds must be observed before commencing tests when the vehicle is locked. Electrical / Mechanical Repair Wheel Bearing: Electrical / Mechanical Repair Rear Wheel Bearing Press for VW/Audi AST tool# 3420 VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle 2008 suggested user price: 25.92 Assenmacher Specialty Tools 1 800 525 2943 Page 4650 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 5384 Electronic Brake Control Module: Locations ABS Control Module With Electronic Differential Lock, (EDL) and Anti-Slip Control (ASC) (From August 2000) ABS control module with electronic differential lock, (EDL) and anti-slip control (ASC) (from August 2000) Page 1335 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 1803 Fuse arrangements in fuse holder, instrument panel left Page 317 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 6207 Example of PR label In this example the vehicle is equipped with the standard suspension components 1GA -arrow-. The PR. number can also be e.g. G08, G29, G46, G76 etc. If you encounter a vehicle prior to the above VINs where the PR. number is missing, use the table below to obtain the correct PR. number prior to aligning the vehicle. Tip: Vehicle PR numbers can also be found in Elsaweb under the Vehicle Specific Information heading. Warranty Information only. Required Parts and Tools No special tools required. No special parts required, always see ETKA for the latest parts information. Page 2696 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2673 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 1910 - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged (dented) dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Fastener/location Tightening torque: Brake caliper to rear axle .............................................................................................................................................................. 65 Nm (48 ft. lbs.) Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 Combination Valve, Checking Air Injection Control Valve: Testing and Inspection Combination Valve, Checking With Manufacturer's Scan Tool Combination valve, checking Special tools, equipment, test and inspection devices; required accessories - VAG 1331 torque wrench (5 - 50 Nm) or equivalent - VAG 1390 manual vacuum pump Test conditions - No error in fault memory - Output diagnostic test mode completed - Vacuum lines and hose connections tight - Vacuum lines not clogged or kinked Test sequence - Remove damping pans - Pull vacuum hose off combination valve on secondary air valve -N112-. - Connect VAG 1390 manual vacuum pump on vacuum hose to combination valve. Page 4827 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 1517 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3734 If indicated voltage does not oscillate: - Remove instrument cluster: - Check wire connection from Engine Control Module (ECM) to Speedometer -G21- according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 4758 The ATF pump is driven via the torque converter (arrows). When installing the torque converter, ensure that the drive engages in the recesses in the ATF pump inner wheel. The torque converter is installed correctly when distance -a- between the transmission housing flange and the contact surface of the torque converter locating pins is 21 mm on 4-cylinder engines 17 mm on 6-cylinder engines It is essential that distance -a- be adhered to for the rest of the installation. The torque converter must not slip forward. Page 1544 Part 1 Page 334 Part 1 Page 4319 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 4733 - Tighten bolt -2- (8 Nm). - Replace circlip -3- if it has been removed. Power Steering Gear, Removing and Installing Steering Gear: Service and Repair Power Steering Gear, Removing and Installing Special tools and equipment ^ 3094 Clamps ^ VAG 1383A ^ Transmission jack ^ VAG 1332 Torque wrench ^ VAG 1331 Torque wrench Power steering gear, instructions: ^ Absolute cleanliness is required when working on power steering system. ^ Thoroughly clean connections and immediate vicinity before loosening. ^ Place parts on a clean surface and cover if not re-installing immediately. ^ Do not use fluffy cloth. ^ Only unpack parts immediately prior to installation. ^ Only use genuine packed Volkswagen parts. Removing - Remove plastic nuts -1-. Page 1563 Vehicle data label is located in the following locations: - Vehicles up to 03.00: In spare wheel recess - Vehicles from 04.00 (Only Jetta vehicles): Next to spare tire wheel well, near left rear wheelhouse - In service booklet Page 3708 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 4622 - VW 681 Extractor lever - T10089 Thrust piece Removing torque converter oil seal Driving in torque converter oil seal until flush Page 4641 Part 1 Page 3066 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 26 Terminal 3 + socket 27 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm Page 6133 Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Page 5051 - Installing refer to Fig. 1 9. Bushing - Only installs in one position 10. Gate selector housing - Install into mounting plate after installing the complete gear lever 11. Bushing 12. Spring 13. Guide bushing - Locate on bushing -1514. Lock washer - Removing refer to Fig. 3 15. Circlip - Removing and installing refer to Fig. 2 16. Spacer sleeve 17. Spring 18. Shift lever 19. Damper 20. Spring clip Fig. 1 Installing cap Press on from side (arrow -1-) - Press opening together to form a slot. Note: If necessary heat cap (e.g. with hot water). Fig. 2 Removing and installing circlip To remove and install the circlip pull gear lever in direction of arrow -A- and at the same time push down spacer bushing onto stop using screwdriver in arrow direction -B-. Note: Do not tilt spacer bushing when pushing down. Carefully release pressure at groove in gear lever for circlip. Page 892 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation High Pressure Sensor G65 High Pressure Sensor G65 Where applicable, High Pressure Sensor G65 transmits a square wave signal to Coolant Fan Control (FC) Control Module J293 at a rate which varies according to the refrigerant system pressure. J293 reacts to the pulse rate of the signal from G65 as follows: If the refrigerant system pressure rises, J293 switches the radiator fan(s) to the second speed. - Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), Coolant Fan Control (FC) Control Module J293 switches the A/C Clutch N25. - On Climatronic equipped models it informs the A/C Display Control Head E87 that the pressure in the refrigerant system is OK and that A/C Clutch N25 can be switched on via J293). On applicable engines, the signal generated by G65 is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance. Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Page 330 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1916 Wheel Bearing: Aftermarket Tools Rear Wheel Bearing Press AST tool# 3420 VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle. - VW/Audi Rear Wheel Bearing Press - Applicable to Newer Golf, Jetta and New Beetle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2136 Oil Pan: Tools and Equipment Hex Ball Socket AST tool# T 10058 Hex ball socket with 5mm tip. - Applicable to: VW/Audi Oil Pan Bolts - Made in Germany Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Right Rear ABS Wheel Speed Sensor Wheel Speed Sensor: Locations Right Rear ABS Wheel Speed Sensor G44 - Right Rear ABS Wheel Speed Sensor Page 301 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 441 Power Distribution Relay: Locations Power Supply (Terminal 30, B+) Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3689 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Service and Repair Clutch Disc: Service and Repair 5 Speed Manual 02J Clutch, Servicing Transmission Removed and equipment required Special Tools - 3190 A Mandrel - 3067 Counter-hold tool Note: Replace clutch discs and pressure plates that have damaged or loose rivets - Select correct clutch plate and pressure plate according to parts list and engine code. Page 3504 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 4559 Control Module: Locations J217 - Transmission Control Module (TCM) Hazard/Turn Signal Flasher Hazard Flasher Relay: Locations Hazard/Turn Signal Flasher RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2380 ^ Cut tie-wrap (arrow), remove blue flat contact housing cover and cloth tape from the overlay harness. ^ Locate the red/violet wire from position 22 (will splice to violet/red wire from coolant level sensor of engine overlay harness). ^ Locate brown/white wire from position 7 (will splice to brown/white wires of engine overlay harness and fuel pump overlay harness). ^ Once located, separate these wires from the wire cluster (when splicing wires, splice these wires first). Instrument cluster overlay harness, general instructions for wire splicing 1. Use Part No: 111971941A (Light yellow crimp connectors) for all positions except brown/white wire. 2. Use Part No: 111971940A (red crimp connector) to connect brown/white wires from engine and fuel pump overlay harnesses to brown and white wire from instrument cluster overlay harness (2 wires connect to 1 wire).) When splicing instrument cluster overlay harness you must: 1. Maintain a harness length of 40cm from the blue connector to the main harness take out point. 2. Stagger crimped connections to maintain a flexible and compact harness. 3. Not all wires in the instrument cluster overlay harness will be used on every vehicle. 4. The overlay harness connector is made to fit many models with various equipment levels. Any wires not used should be folded and taped back into the harness (see above - Unused wiring, taping back to harness). 5. Tape the overlay harness connector next to the factory connector (because wiring leading to instrument cluster may vary in coloring from vehicle to vehicle compared to the overlay harness) 6. When taped side by side, you can easily trace each wire out away from the connectors in pairs (i.e. wire from position one of the overlay harness and wire from position one of the factory harness). 7. Cut original wires from factory harness (ONE AT A TIME) and reattach to the instrument cluster overlay harness. Instrument cluster overlay harness, splicing to instrument cluster ^ Start by placing all wires from factory harness to the left of the steering column. ^ With overlay harness connector taped alongside of instrument cluster harness as shown. This will allow side by side comparison of wire splicing as follows: ^ Locate the red/violet wire from position (22) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness. ^ Cut both wires. Using a light yellow splice connector Part No: 111971941A: ^ Strip, splice and crimp the red/violet wire from position (22) of overlay harness to the violet/red wire from coolant level sensor of engine overlay harness). Testing and Inspection Seat Occupant Sensor: Testing and Inspection Components, Adapting Special tools, testers and auxiliary items required - Vehicle Diagnosis, Testing and Information System VAS5051 - Diagnostic cable VAS5051/1 or VAS5051/3 Work procedure - Select "Guided Fault-Finding" on Vehicle Diagnosis, Testing and Information System VAS5051. After all control modules have been checked: - Press "Go to" button - Select "Function/component selection" - Select "Body" "Body-Interior; Repair" - Select "01 - On Board Diagnostic (OBD) capable systems" - Select "airbag" - Select "Functions": - Select "action" Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: Customer Interest Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 1810 Fuse: Fuse and Fusible Link Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 4757 Torque Converter: Service and Repair 5 Speed Automatic 09A Draining Torque Converter, Draining Special Tools And Equipment - VAG 1358 A Oil extractor If the torque converter has become fouled by abrasion or when performing a major overhaul of the transmission, drain the torque converter as follows: - Extract ATF from torque converter using VAG 1358 A and probe VAG 1358 A/1. Installing Torque converter, installing Tools and Equipment Fan Clutch: Tools and Equipment 32mm Fan Clutch Wrench AST tool# 8032 32mm x 380mm long wrench used for the R and R of any 32mm fan clutch nuts. This tool is applicable to VW, Audi and BMW models with 32mm fan clutch nuts. - Used for R and R of Fan Clutch - Steel Construction - Easy-Grip Handle - Applicable to VW, Audi and BMW Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5779 ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting wheel speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert wheel speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor to speed sensor wiring. Wheel speed sensor on rear axle (drum brakes), removing and installing Removing ^ Raise vehicle. ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect speed sensor to speed sensor wiring. ABS wheel speed sensor wiring to rear axle, removing and installing Required special tools Page 4240 With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 With Manufacturer's Scan Tool Idle Speed: Testing and Inspection With Manufacturer's Scan Tool Idle Speed, Checking NOTE: - Idle speed, ignition timing and CO content are not adjustable. - The idle speed is regulated to specified value by the throttle position sensor in conjunction with the DIS function. - CO content regulated by Oxygen Sensor (O2S) control. Malfunctions in oxygen sensor control are detected in On Board Diagnostic (OBD) and stored as DTCs in DTC memory Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Coolant temperature at least 85 °C See display group 004, display field 3. - Intake air temperature less than 60 °C See display group 004, display field 4. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes - Leave VAG1551 Scan Tool (ST) connected. - Continue running engine at idle speed. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -0- and -1- to input display group number 1 (001) and press -Q- button to confirm input. Indicated on display: (1-4= display fields) System in basic setting 1 -> 1234 NOTE: In the "Basic Setting" function the Evaporative Emissions (EVAP) canister purge regulator valve -N80- is closed and the air conditioner compressor is switched off - Check adjustment conditions for basic setting in display field 4. Page 4938 Wheel Bearing: Service and Repair Rear Wheel Bearings, Servicing Wheel bearings, servicing Wheel bearings, vehicles with front wheel drive, servicing Note: The descriptions and illustrations are for vehicles with disc brakes. - Wheel fittings for vehicles with drum brakes is the same. - All tightening torques and notes are therefore valid for vehicles with drum brakes. 1. Phillips-head screw 2. Brake disc 3. Dust cap - Always replace A perfect seal is only achieved using a new dust cap. Only then is an optimum function and long service life guaranteed. 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace 5. Wheel hub with wheel bearings The wheel bearing and wheel hub are installed together in housing. This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible! 6. Axle beam Page 1545 Part 2 Page 144 - Remove B-pillar lower trim to remove 5 - Door control module, RR For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 6 - Door lock, RR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 7 - Motor for fuel tank lid unlock -V155- remote release Installation position: Under C-pillar trim - To remove, remove trim up to wheel house - Remove with special socket insert T 10010 8 - Rear lid lock Bolted to rear lid - Removing: Remove trim from rear lid. - Remove lock. 9 - Rear lid actuator Bolted to rear lid - Remove with special socket insert T 10010 10 - Door lock, RL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 11 - Coupling station - Installation position: rear roof area, covered by roof trim - Remove roof trim to remove. 12 - Anti-theft alarm horn Installation position: In area of C-pillar covered by trim 13 - Door control module, RL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 14 - Coupling station Installation position: B-pillar - Remove B-pillar lower trim to remove 15 - Door lock, FL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 16 - Controls Installed in door trim - Remove door trim to remove 17 - Door control module, FL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 18 - Antenna - for radio frequency remote control Under left A-pillar trim - Remove A-pillar trim to remove. 19 - Coupling station Installation position: Lower A-pillar, cove red by trim in footwell - Remove left A-pillar lower trim to remove Page 5172 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 3613 If the specified value is obtained: - Change to display group 32 as follows: - Press -C- button. - Press buttons -0-, -3- and -2- to input display group number 32 (032) and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 32 -> 12 - Check oxygen sensor control learned value at idling (additive) in display field 1. - Check oxygen sensor control value at part load (multiplicative) in display field 2. Page 3522 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated EPC Warning Lamp Operation Malfunction Indicator Lamp: Testing and Inspection EPC Warning Lamp Operation Electronic Power Control (EPC) Warning Lamp (malfunction Indicator Lamp For Electronic Accelerator (E-Gas)) In Instrument Cluster, Significance Location of EPC warning lamp Functional check: - Switch ignition on. The EPC warning lamp must light up. If the EPC warning lamp does not light up with the ignition switched on: - Check EPC lamp wiring/EPC lamp bulb using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. If the EPC warning lamp lights up with the ignition switched on, continue check as follows: - Start engine and run at idle. The EPC warning lamp must go out after a few seconds. If the EPC warning lamp does not go out: - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. If no DTCs are stored: - Check EPC lamp wiring using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. Fuse Arrangements In Fuse Holder, Instrument Panel Left Fuse: Application and ID Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 4091 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Locations Page 2510 A/C Pressure Sensor/Switch - Cooling Fan: Locations High Pressure Sensor G65 G65 High Pressure Sensor in engine compartment, right rear, in refrigerant line Service and Repair Brake Bleeding: Service and Repair Brake system, bleeding Vehicles with ABS and ABS/EDL When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled using the VAG 1551 scan tool in function 04, "basic setting". WARNING! Do not exceed a filling pressure of 1 bar (14.5 psi) when filling with brake fluid using pressure bleeder US1116. The brake system will not be completely bled if excessive pressure is used. Notes: ^ Bleeding the brake system on vehicles with ABS is the same as for vehicles with conventional braking systems with the exception of using function 04 to bleed systems that have been completely empty. ^ Brake fluid absorbs moisture from the air and must therefore be replaced every two years. Use only new, unused and approved brake fluid that complies with MVSS 116 DOT4. Notes: ^ Brake fluid is poisonous. Also due to its corrosive effect brake fluid must not come into contact with paintwork. ^ Brake fluid must always be stored in airtight containers. ^ Do not use silicone-based brake fluid (DOT 5). Even the smallest trace can cause severe corrosion in the brake system. ^ Rinse off brake fluid spillages using plenty of water. Brake system, bleeding using US1116 pressure bleeder Special tools and equipment required ^ US 1116 brake bleeder ^ Connect brake filling and bleeding unit. ^ Open bleeder valves in specified sequence and bleed brake calipers. Bleeding sequence 1 Right rear caliper 2 Left rear caliper 3 Right front caliper 4 Left front caliper Vehicles with ABS or ABS/EDL ^ Test drive vehicle and perform at least one brake application sufficient to engage ABS regulation. Brake system, bleeding without pressure bleeder ^ Build-up brake pressure in brake system by pumping brake pedal. ^ Connect hose from bleeder bottle to brake bleeder valve at each wheel in turn. ^ Open bleeder valve. ^ Hold brake pedal down, close bleed screw. Note: The brake fluid level in the reservoir must not fall below the MIN mark during bleeding. ^ Release brake pedal. ^ Repeat operation until brake fluid flows without air bubbles. Page 4695 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 170 Part 2 Page 2069 - Remove mounting screw(s) -arrow-. - Lift engine covers -A- and -B- (where applicable) from engine. 2.8L - 4V - Unclip and lift engine cover -1- from engine. - Mark running direction of ribbed belt if it will be used again. - Install hex bolt -A- as illustrated and tighten until ribbed belt tension is relieved. - Remove ribbed belt. Ribbed belt, installing Page 2192 T 40001-7 - Puller Claw for VW 2.0 Turbo; Accessory Arm 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 3780 Production Solution No production change required. Service Tip: Oil level MUST be correct, if overfilled, level should be adjusted to the proper level prior to performing procedure. Adjusting oil level is NOT covered by Warranty. Exhaust system damage from outside influences is NOT covered by Warranty. The following steps are to be followed before replacement of catalytic converters. Inspect complete exhaust system for broken or missing components, loose clamps, etc. Repair as necessary. If vehicle has MIL ON, investigate fault memory without erasing codes. Before performing any repair, make a print out of fault memory including: Address 01 fault memory (including ECM information) Address 01 Measuring Value Block 46 (and 47, if applicable) Tip: For 4 bank systems such as Phaeton W12, Display groups 46 and 47 must be printed out from addresses 01 and 11. OBD freeze-frame mode 2, and 6. Tip: For OBD, see Repair Manual - Fuel Injection & Ignition 2.0 Liter 4yl. 2V Generic Scan Tool Engine Code(s). AEG, BBW, BEV, ST-Generic Scan Tool Steps for printing OBD from the touch screen: Select "OBD". Select "mode 2". Select all PIDS displayed (use scroll bar if necessary). Select right arrow key to display results. Select "print", and then save result. Save results for modes 2 and 6. Print - self diagnosis log. DO NOT replace catalyst if software updates related to catalyst are available. Check for applicable Technical Bulletins or Campaigns. Perform any applicable software updates available through Technical Bulletins or Campaigns. If other faults related to fuel mixture, oxygen sensor or misfire are present: DO NOT replace catalyst(s). Correct condition, erase DTCs, reset readiness codes and monitor measured value block (MVB) in 46, 47 until complete ("Test OK or Test n OK"). If after repair of other faults, diagnostic result in MVB 46 (and 47, if applicable) is/are OK: DO NOT replace catalyst(s). Page 4976 Drive shaft protective cover to engine 35 Nm - Top up transmission oil. Page 692 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 845 Oil Pressure Sender: Testing and Inspection refer to Oil pressure and oil pressure switch, checking Special tools, equipment, test and, inspection devices; required accessories Special Tools ^ V.A.G 1342 Oil pressure tester ^ V.A.G 1527 B Diode test lamp ^ V.A.G 1594 A Supplemental measuring tool set Function of the Dynamic Oil Pressure Warning System The oil pressure switch is open without pressure and is closed when the operating pressure is reached. The oil pressure warning is actuated approximately 10 seconds after the ignition is turned on. Oil pressure warning turn-on delay: approximately 3seconds. Oil pressure warning turn-off delay: approximately 5 seconds. Checking the indicator light for operation with oil pressure After the ignition is turned on, the indicator light (K3) in the instrument panel must light for approximately 3 seconds and then extinguish. The test ends when the engine starts running. Warning criteria Warning is provided both visually (blinking indicator light) and acoustically (buzzer sounds three times). This occurs under the following operational states: ^ Ignition ON, engine stopped, oil pressure switch closed ^ Engine speed above 1500/min, oil pressure switch open Notes: ^ The indicator light is not switched off if the engine speed exceeds 5000 rpm, not even if the oil pressure switch is closed. The indicator light will be shut off again when the engine speed drops below 5000 rpm. ^ If the oil pressure switch is only opened for 0.5-3.0 seconds when the engine speed is over 1500 rpm, this fact will be stored in the instrument cluster processor. If this state occurs three times while the engine is running, the warning will be triggered and will not be cleared even under 500 rpm. The warning will be cleared when the oil pressure switch is closed for more than 5 seconds and the ignition is turned off. Test conditions ^ Oil level OK (checking refer to, Fig. 2) Coolant FC (Fan Control) Control Module J293 Control Module HVAC: Description and Operation Coolant FC (Fan Control) Control Module J293 Coolant FC (Fan Control) Control Module J293 NOTE: Available in different construction styles, some separate some installed on radiator fan. This control module switches on and off the A/C clutch and therefore the A/C compressor. It switches the coolant fans and (in vehicles with High Pressure Sensor G65 or A/C Pressure/temperature Sensor G395) calculates the pressure in the refrigerant circuit. Page 475 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1448 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 5228 Test Step 1 Page 6215 Vehicles with front wheel drive Rear axle is not adjustable. 4. Check toe at front axle, adjust if necessary 5. Verify vehicle suspension factory code Following applies to all suspension versions Check vehicle trim height (zero position), if a measurement is out of tolerance, before adjusting = below Vehicle trim height, Zero Position If vehicle is out of specification check trim height (see illustration). Example: a vehicle equipped with an automatic transmission could stand slightly lower to one side. This is normal due to installed position of components and weight distribution. ^ Check item -a- on both left and right sides, correct if necessary. It is possible to correct trim height imbalance for front axle by adding weight to top of strut tower and/or adding weight in trunk for rear axle, example: sand bags can be used, approx. 10 kg (22 lb.) Factory codes, explanation Various suspension versions are available as optional equipment. These are identified by factory codes. Vehicle data label lists suspension version factory codes. Example of vehicle data label In this example vehicle is equipped with standard suspension 1GC (arrow). Page 2770 Clutch Switch: Testing and Inspection With Generic Scan Tool Checking Signal From Clutch Vacuum Vent Valve Switch Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Clutch Vacuum Vent Valve Switch -F36- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Remove driver-side storage compartment. - Disconnect connector from Clutch Vacuum Vent Valve Switch -F36-. Vehicles with 2-pin clutch vacuum vent valve switch - Measure resistance between terminals 1 + 2 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 4941 - Pull off wheel bearing/wheel hub unit from stub axle. - A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Caution: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 ab. - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake disc. Page 1851 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 5028 When moving gear lever selector shaft must move approx. 1 mm (in direction of arrow). If not, adjust selector mechanism. Locations Air Door Actuator / Motor: Locations V154 - Servo motor for fresh/recirculating air door Page 5438 ^ Control module connector is not disconnected before On Board Diagnostic (OBD) 12 Connection for brake line ^ Hydraulic unit to left front brake caliper 13 Connection for brake line ^ Hydraulic unit to right rear wheel cylinder/ brake caliper 14 Connection for brake line ^ Hydraulic unit to left rear wheel cylinder/ brake caliper 15 Connection for brake line ^ Hydraulic unit to right front brake caliper 16 Brake line ^ Brake master cylinder/pressure rod piston circuit to hydraulic unit 17 Brake line ^ Brake master cylinder/floating piston circuit to hydraulic unit 18 Hex nut, self locking, 20 Nm (15 ft. lbs.) 19 Hex nut, self locking, 20 Nm (15 ft. lbs.) 20 Seal ^ Always replace 21 Vacuum hose ^ Install in brake booster 22 Sealing plug 23 Hex nut, self locking, 20 Nm (15 ft. lbs.) 24 Seal ^ For brake booster 25 Boot ^ Ensure boot is properly seated or suction noises may be noticed 26 Bracket Brake lines from brake master cylinder to hydraulic unit, connecting Fig. 1 Vehicles with ABS A Secondary piston circuit B Primary piston circuit 1 Hydraulic unit to right front brake caliper 2 Hydraulic unit to left rear wheel cylinder/brake caliper 3 Hydraulic unit to right rear wheel cylinder/brake caliper 4 Hydraulic unit to left front brake caliper Fig. 2 Vehicles with ABS/EDL A Secondary piston circuit Central Control Module For Comfort System Connectors Body Control Module: Locations Central Control Module For Comfort System Connectors Central control module for comfort system Page 5694 Page 4313 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3509 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Service and Repair Fuel Filler Cap: Service and Repair 1 - Cap Secured with strap from MY 2000 2 - Sealing ring Replace if damaged 3 - Retaining screw 4 - Fuel filler door module With rubber seal 5 - Vent line Black - Make sure tight fit 6 - Ground connection Make sure tight fit 7 - Vent line White - Make sure tight fit - To activated carbon canister, item -3- Press release tabs on connecting piece to remove from flange 8 - Gravity/overflow - valve Remove by clipping valve upwards out of its fitting Checking valve passage - Valve vertical. open Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: Customer Interest Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 934 Part 1 Page 2809 - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wire: Vehicles with engine code AFP - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Vehicles with engine code BDF - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Continuation for all vehicles Range A displays resistance values for the temperature range of 0...50 degree C, range B displays resistance values for the temperature range of 50...100 degee C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. Page 4414 Test Step 10 - 11 Page 3641 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Relay Locations Compiled From Every Wiring Section 1998-2004 Fuel Pump Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2472 1. Pressure cap 2. O-Ring 3. Coolant recovery bottle 4. 10 Nm 5. Upper coolant pipe 6. To heat exchanger 7. Throttle valve control unit (J338) 8. To upper coolant hose 9. To upper radiator 10. Gasket 11. To lower radiator 12. Thermostat housing 13. Coolant feed pump (V51) 14. From heat exchanger 15. 25 Nm 16. Oil cooler 17. Screw plug 18. Coolant pipe 19. Coolant pump 20. 15 Nm 21. Pulley for coolant pump 22. 25 Nm 23. To Y-branch of - heat exchanger/coolant feed pump Page 5355 Page 5558 ^ Press piston into brake caliper housing using piston resetting tool. The protective seal outer sealing lip must slip into the piston groove. Page 3977 Fuel Pump Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 376 Channel 03 Adaptation 90 -> Changed value is stored - End consumption indicator adaptation with -> button. Indicated on display: Rapid data transfer HELP Select function XX NOTE: A false entry switches the tester to "Select function" mode. If the following display appears: Function Is unknown or -> cannot be carried out at the moment - Press -> button. - Select function "10 - Adaptation" and adaptation channel 03 again. - Carry out corrections to consumption indicator and confirm with Q button. Page 1270 Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. - Check wires between test box and 6-pin connector (to control module) for open circuit according to wiring diagram. Terminal 1 + socket 70 Terminal 2 + socket 71 Terminal 5 + socket 51 Terminal 6 + socket 52 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7, - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5699 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 6403 Fig. 3 Rear control arm mount, installation position One of embossed arrows points toward projection (arrow A) on control arm. Fig. 4 Rear control arm bushing, pressing out in Page 18 - Connect VAG 1551 Scan Tool, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 17, "Instrument cluster". - Press -Q- button to confirm input. - Press -> button until "Select function" appears in display. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display Rapid data transfer Q 08 - Read Measuring Value Block - Press -Q- button to confirm input. Indicated on display Read Measuring Value Block Input display group number XX - Press button -0- once and -2- twice to enter "display group 22". - Press -Q- button to confirm input. - Indicated on display Read Measuring Value Block 22 -> 1112 Page 2208 NOTE: Take note of timing grooves used for timing the engine. - Insert Camshaft Guide 3268 Tool into both shaft slots. Capacity Specifications Final Drive Fluid: Capacity Specifications Final Drive Capacities 01M Transmission Initial Filling .......................................................................................................................................... ............................................ 0.75 liter (0.80 quarts) Page 1246 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin harness connector to Motronic Engine Control Module (ECM) according to wiring diagram. Terminal -3- + socket 68 - Terminal -4- + socket 69 Wire resistance: max. 1.5 ohms - Check wiring at harness connector terminals -3- + -4- for short circuit to terminals -1- + -2according to wiring diagram. Specified value: infinity ohms If no wiring fault is detected: - If no malfunction is found in the wiring, replace Engine Control Module (ECM). Heater Check Heated Oxygen Sensor (HO2S) After Three Way Catalytic Converter (TWC), Checking Special tools and equipment - VAG1551 Scan Tool (ST) Or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements Page 6271 - -Install suction hose and spring clip. (Arrow A) must align with casting seam arrow. Spring clip must close off mark -arrow B-. - Install new O-rings on banjo bolt. - Tighten banjo bolt to 30 Nm (22 ft. lbs.). Continue installation in reverse sequence Page 1871 Page 4327 - Tighten both bolts -arrows B- to 25 Nm. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Reconnect Ground strap to battery. - Check selector mechanism. - Enter radio code. Service and Repair Wiring Harness: Service and Repair Wiring Harnesses And Connectors, Repairing CAUTION! Wiring harness and connector repairs must only be performed using repair kit VAS 1978! Repair kit VAS 1978 contains a detailed instruction manual that outlines all aspects of wiring harness and connector repair. Always follow wiring harness and connector repair measures. Wiring Harnesses And Connectors, Repair Measures CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. - Before beginning wiring and connector repairs, determine and rectify the cause of damage, eg.: pinched between metal parts, Page 3895 Fuel Injector: Description and Operation Fuel Injection and Ignition, General Information Servicing ignition system. See: Ignition System/Service and Repair/Ignition System, General Information NOTE: - The Engine Control Module (ECM) has On Board Diagnostic (OBD) capability. Before carrying out troubleshooting and repairs, DTC memory must be checked. Vacuum hoses and connections must also be checked (unmetered air). - Fuel lines in the engine compartment must only be secured using spring type clips. The use of clamp or screw type clips is not permissible. - Components marked with a * are checked via the On Board Diagnostic (OBD). - Components marked with a **can be checked with output Diagnostic Test Mode (DTM). - For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary. - Do not use sealants containing silicone. Particles of silicone drawn into the engine will not be burned in the engine and will damage the oxygen sensor. - When performing some repairs, it is possible that the control module will recognize a malfunction and store a DTC. After completing all checks and repairs DTC memory must be checked and, if necessary, erased and the readiness code must be generated. - Safety precautions See: Service Precautions/Technician Safety Information - Rules of cleanliness. See: Service Precautions/Vehicle Damage Warnings - Technical data. - Checking engine operating mode. Page 2228 - Install lower timing cover, Torque: 6 mm bolts to 10 Nm, 8 mm bolts to 25 Nm CAUTION: Do not damage Cylinder Head Gasket, when installing timing covers. - Re-install preliminary components, see end. With engine installed, cylinder head removed - Using mounting bolt for vibration damper, align crankshaft with mark for TDC cyl. 1 - arrow -. Page 3287 Information Bus: Reading and Clearing Diagnostic Trouble Codes With Manufacturer Scan Tool Diagnostic Trouble Code (DTC) Memory, Checking (function 02) NOTE: DTCs stored in memory along with corresponding malfunction descriptions can only be displayed by initiating the On Board Diagnostic program and checking DTC memory (function 02). - Connect VAG 1551 Scan Tool, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 19, "Gateway". - Press -Q- button to confirm input. - Press -> button until "Select function" appears in display. - Switch on printer with the PRINT button (indicator lamp in button lights up). Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -2- to select "Check DTC memory" function 02. Indicated on display: Rapid data transfer Q 02 - Check DTC memory - Press -Q- button to confirm input. The number of stored DTCs appears in the display. X DTC's recognized! Stored DTCs are displayed and printed out one after another. - Check print-out against DTC table and repair all malfunctions as necessary. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/VAG Code Charts/CAN Bus If "No DTC recognized" is displayed the program will return to the initial position after pressing -> button. No DTC recognized! Indicated on display: Rapid data transfer HELP Select function XX If something else is displayed: - See: Scan Tool Testing and Procedures/End Output (Function 06) - Switch ignition off - Disconnect VAG 1551 from Data Link Connector (DLC). Without Manufacturer Scan Tool The manufacturer does not provide a procedure for reading diagnostic trouble codes without a scan tool. Diagnostic Trouble Code (DTC) Memory, Erasing (Function 05) Diagnostic Trouble Code (DTC) Memory, Erasing (function 05) NOTE: After DTC memory is erased, its contents are automatically output. If DTC memory cannot be erased, check DTC memory again and repair malfunction. Prerequisites - DTC memory checked. See: Diagnostic Trouble Code (DTC) Memory, Checking (Function 02)/With Manufacturer Scan Tool - All malfunctions repaired. Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 210 Seat Heater Control Module: Service and Repair Switches In Instrument Panel, Removing And Installing Switches consists of a switch housing and trim plate with relevant symbol. The trim plate is clipped onto the switch housing. If the trim is released instead of the switch during removal, the trim must be re-clipped onto the switch housing afterwards. Remove switches with connected wiring from instrument panel opening prior to disconnecting electrical connection on rear of switch. If necessary, temporarily remove switch to the left of of the switch to be removed/replaced to allow sufficient access to the wiring. NOTE: Switch blank-out covers (where applicable) are removed in the same manner as switches. CAUTION! - Be careful not to damage instrument panel when removing switch. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. Heated Seat Control Module/regulator, Removing And Installing Removing Page 1321 Vehicle Speed Sensor: Testing and Inspection With Generic Scan Tool Checking Speed Signal Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Battery voltage must be at least 11.5 volts. - Speedometer -G21- must be OK. Test sequence NOTE: To test speed signal, vehicle must be driven. Doing this requires a second person. WARNING: Secure Scan Tool (ST) on the rear seat and have operated from there by second technician. - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 13: Vehicle speed". - Perform a road test, and have the 2nd person observe the indication on the display. - Check specified value of the vehicle speed: - End diagnosis and switch ignition off. If no speed is indicated: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - To measure voltage, connect multimeter between sockets 2 (Ground -GND-) +54 (speed signal) of test box. - Raise vehicle at front left. - Switch ignition on. - Rotate front wheel, and observe voltage indicated while doing so. Specified value: 0.0 to at least 4.0 V, fluctuating NOTE: The right front wheel must not turn during this, hold it steady if necessary. Page 5771 Wheel Speed Sensor: Locations Left Front ABS Wheel Speed Sensor G47 - Left Front ABS Wheel Speed Sensor Page 17 Indicated on display Rapid data transfer HELP Select function XX Measuring Value Blocks (Function 08) Read Measuring Value Block (function 08) Use this function to determine immobilizer system status. Page 5189 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 202 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Service and Repair Timing Component Alignment Marks: Service and Repair Please see Timing Chain / Service and Repair for complete procedures to set/adjust the camshaft, intermediate shaft and Crankshaft timing alignment. See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Chain/Service and Repair. Page 4525 17. Bolt, 14 Nm 18. Supporting plate - Installing see Fig. 3 19. Guide plate - Insert before supporting plate see Fig. 3 20. Transmission housing - It is not necessary to remove the drive gear to disassemble the parking lock 21. O-ring - Always replace 22. Multi-function Transmission Range (TR) switch -F125 - Removing and installing see Fig. 7 - Tested in the vehicle by On Board Diagnostic (OBD) 23. Retainer - For multifunction TR switch 24. Bolt, 10 Nm 25. Mounting bushing - Removing see Fig. 5 - Installing see Fig. 6 26. O-ring - Always replace 27. Vehicle speed sensor -G68 - Removing and installing with transmission installed- see Fig. 9 - Tested in the vehicle by On Board Diagnostic (OBD) 28. Bolt, 10 Nm 29. O-ring - Always replace 30. Transmission vehicle speed sensor -G38 - Removing and installing see Fig. 8 - Tested in the vehicle by On Board Diagnostic (OBD) 31. Bolt, 10 Nm 32. Retainer - For wire to transmission vehicle speed sensor - Secure with bolt-item 31 33. Retaining clip - For wire to vehicle speed sensor 34. Lever - For selector shaft 35. Bolt, 10 Nm 36. O-ring - Pry out with screwdriver - Drive in flush with VW 423 37. Breather cap 38. Breather 39. Breather pipe - Remove using pliers - Drive onto stop with drift VW 460/2 Fig. 1 Driving spring pins (arrows) out and in Driving out Drive spring pin for engaging lever and spring pin for detent segment out only far enough to remove selector shaft. Note: Driving spring pin out too far may cause spring pin of engaging lever to drop into planetary gearbox. Page 3105 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 3093 Brake Signal: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 698 Part 2 Page 1863 The display shows: - On the display, press "10 - Adaptation" -arrow-. The display shows: - On the display keypad press -arrow- keys 0 and 2. With adaptation channel 02 the service interval indicator is reset. - Confirm the entry by pressing key Q on the display keypad. Page 6213 Alignment: Testing and Inspection Wheel alignment, checking General It is always necessary to check alignment of all four wheels to ensure correct driving characteristics. Otherwise correct vehicle performance is not guaranteed and an off center steering wheel may exist. NOTE: ^ Perform vehicle alignment only after 1000 - 2000 km (600 - 1200 miles) to allow suspension time to settled. ^ Otherwise precise settings are difficult to reach. Steering wheel and steering column are marked. A- Line on steering wheel B- Punch mark on steering column These positions must not be changed! Steering rack center position is not ensured otherwise. Steering columns supplied as spare parts do not have a center punch mark. These spare part steering columns must be marked after vehicle alignment and test drive. Tightening torque: Multi-point socket-head bolt 50 Nm (37 ft. lbs.). Wheel alignment is necessary if any of the following are true. ^ Vehicle is not tracking properly ^ Damage from an accident. ^ Tire wear on one side. A/C Pressure Switch F129 High Pressure Sensor / Switch: Locations A/C Pressure Switch F129 F129 A/C Pressure Switch - engine compartment, right rear Service and Repair Air Cleaner Housing: Service and Repair 1 - Harness connector Black, 2-pin - For Positive Crankcase Ventilation (PVC) heating element -N79- Check heater element voltage supply between terminals 1 and 2 with engine running: - Specified value: at least 11.5V 2 - Connecting hose For air circulation of fuel injectors 3 - Intake hose Note installation position 4 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-* Checking -G70-. Refer under "Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor", See: Air Flow Meter/Sensor/Testing and Inspection - Checking - G42-. Refer under "Powertrain Management/Computers and Control Systems/Air Temperature Sensor", See: Computers and Control Systems/Intake Air Temperature Sensor/Testing and Inspection - Sensor and harness connector terminals are gold plated 5 - Harness connector Black, 5 pin - Sensor and harness connector terminals are gold plated 6 - Seal Always replace if damaged 7 - Air cleaner upper section Page 4434 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 4129 Page 1391 Impact Sensor: Locations Left Rear Side Airbag Crash Sensor G256 - Left rear side airbag crash sensor Page 5038 Special tools and equipment - VW 439 Guide pin - VW 401 Thrust plate - VW 408 A Press tool - VW 447 i Thrust plate - 3129 Fitting tool Special tools and equipment Page 4891 Final Drive Fluid: Fluid Type Specifications Final Drive Fluid Type Synthetic Oil SAE 75W90 Part Number: ....................................................................................................................................... .............................................. 0.5 liter G 052 145 A1 Part Number: .................................................... ................................................................................................................................. 1.0 liter G 052 145 A2 Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (Automatic transmission) Page 4402 Test Step 5 - 6 Page 1710 - Pull cover -1- off in direction of arrow. - With ignition switched off, connect tester VAS 5051 to diagnostic connection using cable VAS 5051/3. - Switch tester on. The tester requires approx. 5 minutes to warm up. Switch ignition on. - Select mode of operation: press button on touch screen for "Vehicle self-diagnosis". - Select vehicle system: select "02 - gearbox electronics" on touch screen. - Select diagnostic function: at this point, all diagnostic functions are available. - Select "08 - read measured value blocks" on touch screen. - Press button on touch screen for" basic settings" and continue to display zone for ATF temperature. Test procedures available on the V.A.G. 1551 are described below. Connect V.A.G 1551 Scan Tool and enter address word "02 Transmission electronics" and advance until "Select function XX" is indicated on display. Indicated on display Press keys O and 8 (The function "Read measured value block" is selected with 08). Indicated on display Confirm entry with key Q. Indicated on display Press keys O and 2 (002 selects "Display group number 002"). - Confirm entry with Q key. Indicated on display The third display zone shows the ATF temperature. Note: The ATF temperature must not be more than approx. 30°C at start of test. - Start engine. - Raise vehicle. Page 2453 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 3051 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Page 1250 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin connector according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 4-pin harness connector terminal -1- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms With Generic Scan Tool Oxygen Sensor And Oxygen Sensor Control Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 310 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 5619 Page 4264 DTCS linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the reflash procedure first. CAUTION! The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc. If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming" (flashing) procedure: ^ Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to have been tuned, and that any damage caused by the tuning of the ECM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties. Page 2843 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin harness connector to Motronic Engine Control Module (ECM) according to wiring diagram. Terminal -3- + socket 68 - Terminal -4- + socket 69 Wire resistance: max. 1.5 ohms - Check wiring at harness connector terminals -3- + -4- for short circuit to terminals -1- + -2according to wiring diagram. Specified value: infinity ohms If no wiring fault is detected: - If no malfunction is found in the wiring, replace Engine Control Module (ECM). Heater Check Heated Oxygen Sensor (HO2S) After Three Way Catalytic Converter (TWC), Checking Special tools and equipment - VAG1551 Scan Tool (ST) Or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Service and Repair Muffler: Service and Repair For further information regarding this component please refer to Exhaust Systems; Service and Repair. Page 465 Body Control Module: Locations J393 - Central Control Module For Comfort System J393 - Central control module for comfort system Page 392 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5091 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Page 4863 - Pull off supply hose -A- to brake fluid reservoir and seal. - Pry clip -B- for pipe/hose assembly out from master cylinder. - Pull line/hose assembly -C- from master cylinder and seal. - Remove driver's side lower dash cover. Refer to Body and Frame. Remove complete clutch pedal mounting bracket as follows: Remove nuts (arrows -1-) for connecting plate -A- and remove plate. - Remove nuts (arrows -2-) for mounting bracket B- and remove bracket. Capacity Specifications Final Drive Fluid: Capacity Specifications 02J Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.0 liters Transmission code: DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF Type ..................................................................................................................................................... .......................... G51 SAE 75w-90 (synthetic oil) Transmission codes: DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ..................................................................................................................................................... .......................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.3 liters Type .................................................................... ........................................................................................................... G51 SAE 75w-90 (synthetic oil) Page 5957 - Remove lower hex bolt -2- after first removing the noise insulation. - Remove bolts -arrows- and remove middle cover of engine compartment noise insulation. - Remove hex nut, unclip securing clips -arrows- and remove left-hand engine compartment section of noise insulation. - Remove brackets/retainers for power steering pressure pipes/hoses and place to side. - Remove lower hex bolt -2- (M12 x 180 mm). When installing tighten hex bolt to 65 Nm. - Take starter out downward. Installing Page 4914 10. Clamp - For triple rotor star - Installed to left side 11. CV joint boot - Check for punctures and chafing 12. Axle shaft 13. Spring washer - Larger diameter faces thrust washer 14. Thrust washer 15. Circlip - Install in shaft groove - Always replace 16. Outer constant velocity joint - Only replace complete - Installing: drive onto shaft with plastic hammer until compressed circlip seats - Greasing - Checking Page 2182 Oil Pressure Sender: Testing and Inspection refer to Oil pressure and oil pressure switch, checking Special tools, equipment, test and, inspection devices; required accessories Special Tools ^ V.A.G 1342 Oil pressure tester ^ V.A.G 1527 B Diode test lamp ^ V.A.G 1594 A Supplemental measuring tool set Function of the Dynamic Oil Pressure Warning System The oil pressure switch is open without pressure and is closed when the operating pressure is reached. The oil pressure warning is actuated approximately 10 seconds after the ignition is turned on. Oil pressure warning turn-on delay: approximately 3seconds. Oil pressure warning turn-off delay: approximately 5 seconds. Checking the indicator light for operation with oil pressure After the ignition is turned on, the indicator light (K3) in the instrument panel must light for approximately 3 seconds and then extinguish. The test ends when the engine starts running. Warning criteria Warning is provided both visually (blinking indicator light) and acoustically (buzzer sounds three times). This occurs under the following operational states: ^ Ignition ON, engine stopped, oil pressure switch closed ^ Engine speed above 1500/min, oil pressure switch open Notes: ^ The indicator light is not switched off if the engine speed exceeds 5000 rpm, not even if the oil pressure switch is closed. The indicator light will be shut off again when the engine speed drops below 5000 rpm. ^ If the oil pressure switch is only opened for 0.5-3.0 seconds when the engine speed is over 1500 rpm, this fact will be stored in the instrument cluster processor. If this state occurs three times while the engine is running, the warning will be triggered and will not be cleared even under 500 rpm. The warning will be cleared when the oil pressure switch is closed for more than 5 seconds and the ignition is turned off. Test conditions ^ Oil level OK (checking refer to, Fig. 2) Page 96 - Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM). - Press mix button briefly again. ^ Screen indicates number of stations broadcasting close to frequency band of selected station. ^ As the number increases for [mp] and (adj], static and signal crossing will increase. To exit service mode: - Depress and hold the mix button or switch radio OFF then back ON Navigation units ^ No internal diagnosis functions. Continue to antenna lead diagnosis. Section 3 - Antenna Lead Diagnosis After initial radio diagnosis using internal service functions, use the following procedures: - Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base. - Check for proper connection. (follow steps for your type of system). - For all systems, locate cable end-point at either diversity box or antenna mast base. - Disconnect cable from either diversity box or antenna mast base. - Carefully ground center wire in cable to chassis. If reception returns: ^ Cable and radio are ok. Page 5330 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 4126 Part 2 Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 4739 Shift Cable: Service and Repair 5 Speed Automatic 09A Selector lever cable, removing and installing Removing Shift selector lever into "P" position. - Pull selector lever cable -1- upward off lever/selector shaft -4-. - Remove circlip -3- at support bracket. - Remove selector lever cable -1- from retainer -arrow- on engine. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. Page 4089 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Page 3007 8 - 6 Nm (53 in. lb) 9 - Filter element 10 - Air cleaner lower section 11 - Air duct 12 - 10 Nm (ft lb) 13 - O-ring Always replace if damaged 14 - Intake hose Ensure seated tightly - Press together at front to release - To Secondary Air Injection (AIR) pump motor -V101-: 15 - Connecting hose For crankcase breather - From breather housing on cylinder head cover 16 - Connecting hose Note installation position - From T-piece connection on intake manifold upper section /Evaporative Emissions (EVAP) canister purge regulator valve -N8017 - Positive Crankcase Ventilation (PVC) heating element -N79- For crankcase breather 18 - To throttle valve control module -J338-* Page 472 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1247 - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -0button to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -4- and -1- to input display group number 41(041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 4. Page 1778 Power Steering Fluid: Service and Repair Power steering fluid level, checking: Requirements: ^ Engine at normal operating temperature ^ Vehicle stationary ^ Front wheels in the straight ahead position. Inspection Service: Fluid level between "min." and "max." markings. - Top up with hydraulic oil G 002 000 if necessary. Note: If the oil level has dropped to the "min." marking, the power steering should be checked. It is not sufficient simply to top up the hydraulic oil. Page 2694 Page 1809 S179 - Fuse -7- (30) in fuse bracket/battery S180 - Fuse -8- (30) In Fuse Bracket/Battery S180 - Fuse -8- (30) in fuse bracket/battery Page 550 - Perform resistance measurement again between test box sockets 77 + 79: Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Terminal Resistance For CAN-Bus, Checking Function The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm Page 2855 Learning prerequisites for part load: - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C If the specified value is obtained: - Change to display group 33 as follows: - VAG1551: Press button 3 - VAG1552: Press button up arrow Indicated on display: (1-2 = display fields) Read Measuring Value Block 33 -> 12 - Observe Oxygen Sensor (O2S) control in display field 1. If the specified value is obtained: Display Group 033 If the specified value is obtained: 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 3219 Page 3899 - Replace O-rings on all fuel injectors and lightly moisten with clean engine oil. - Insert fuel injectors vertically and in the correct position into the fuel rail and secure using retaining clips. - Fit fuel rail with fuel injectors installed and secured onto intake manifold lower section and press in evenly. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Checking Fuel Injectors For Injection Quantity And Proper Seal Recommended special tools and equipment - VAG1348/3A remote control with VAG1348/3-2 adapter cable - V.A.G 1602 tester for quantity of injected fuel Without illustration: - VAG1594A connector test kit Test requirement - Fuel pressure must be OK, fuel pressure regulator and retaining pressure, checking. See: Fuel Pressure/Testing and Inspection Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. - Then, remove the fuel distributor completely (fuel lines remain connected) With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 4581 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 1716 Fluid - A/T: Service and Repair 5 Speed 09A Transmission ATF, Replacing - Remove sound insulation tray. - Place drip tray under transmission. - Remove drain plug (arrow) in transmission housing. - Drain ATF. - Screw in drain plug with new seal and tighten to 45 Nm. If ATF needs to be topped up, then only ATF with Part No. G 052 990 A2 may be used. - Fill with approx. 2.5 liters of ATF (G 052 990 A2) through filler pipe. - Start engine and shift through all selector lever positions with vehicle stationary. - Check and top up ATF level. Page 4339 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4993 - The engine/transmission angle has changed and therefore the lower edge of the oil fill hole -1- is located below the new oil level -2-. - To properly check oil level, transmission must be drained completely and re-filled. Tip: The transmission housing must be cleaned and dried before servicing. Shift fork pins must be removed in order to drain transmission. Selector shaft, securing ^ Remove air cleaner housing. ^ Remove sound insulation. ^ Clean and dry transmission. ^ Secure selector shaft so that the position of shift fork pins can not move: ^ Press selector shaft down arrow -1^ While selector shaft is held in down position, turn bracket -A- upward (clockwise) in direction of arrow -2- and press inward until the bracket latches in selector shaft. Tip: Use a clean 3.0L container with graduated markings to catch draining oil Transmission, draining Page 5160 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 3847 Idle Speed: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 4081 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 748 Sunroof / Moonroof Switch: Service and Repair Sunroof Regulator (Switch) -E139-, Removing and Installing Sunroof Regulator (switch) -E139-, Removing And Installing NOTE: Sunroof regulator -E139- cannot be replaced individually. The complete interior/reading light unit with switch assembly must be replaced. Page 6335 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1695 Final Drive Fluid: Fluid Type Specifications 02J Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.0 liters Transmission code: DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF Type ..................................................................................................................................................... .......................... G51 SAE 75w-90 (synthetic oil) Transmission codes: DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ..................................................................................................................................................... .......................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.3 liters Type .................................................................... ........................................................................................................... G51 SAE 75w-90 (synthetic oil) Page 1408 Seat Belt Buckle Switch: Locations Left Front Seat Belt Microswitch F140 - Left front seat belt microswitch Engine Controls - Silicone Sealer/Lubricant Precautions Oxygen Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Engine Controls - Silicone Sealer/Lubricant Precautions Oxygen Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 4368 1. Circlip - Different thickness - Mark after removing and insert at same point 2. Thrust plate - Install with stepped side facing circlip 3. Inner plate 4. Outer plate 5. Pressure plate - Install with peened corrugated washer facing piston 6. Corrugated washer - Peened to pressure plate (item 5) 7. Securing ring - Removing and installing see Fig. 1 8. Piston cap - Sealing lips are vulcanized to piston cap - Moisten with ATF before installing - Turn piston cap slightly when installing - When removing and installing press down and fit securing ring (item 7) 9. Spring - Seat between piston and piston cap 10. Piston - Sealing lips are vulcanized to piston - Moisten with ATF before installing Page 4356 Clutch: Service and Repair Low Clutch 4 Speed Automatic 01M 1st to 3rd gear clutch -K1-, disassembling and assembling Special tools and equipment - VW 401 Thrust plate - VW 402 Thrust plate - VW 412 Press tool - VW 442 Thrust pad - 40-203/1 Tube, split Note: The clutch should only be disassembled for cleaning or to visually check parts. The clutches -K1- and -K3- are pressed together. Pressing -K1- off-K3- Pressing -K1- onto -K3- Page 1269 - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Oxygen Sensor (O2S) And Oxygen Sensor Control Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. - The oxygen sensor (before catalytic converter) has a static regulation and can be differentiated from the oxygen sensor behind catalytic converter via a 6-pin connector. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degrees C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor before catalytic converter must be OK. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor Before TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals - End diagnosis and switch ignition off. If specified values are not obtained: - Test oxygen sensor wires. Page 1956 Camshaft Gear/Sprocket: Tools and Equipment Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) - AST Tool # T 40001-6 Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) AST tool# T 40001-6 Puller Claw - Accessory Arm (25mm spread). Used in conjunction with T 40001 Puller and T 40001-7 Arm. (Not part of the T 40001 kit; order separately.) Applicable to: VW/Audi; 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT); Used to remove Camshaft Gear/Wheel. - Made in Germany - Contact AST for pricing - Applicable; VW/Audi 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT) - Thin fingers on end of Claw to fit into the tight area behind the Cam Wheel Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: Page 2718 - Reduced Transmission life. Page 1903 - Remove brake carrier with brake caliper. To do this remove brake caliper and hang up with wire or similar. - Mark installation position of bolts from ball joint to control arm. - Remove bolts - arrows - . - Press axle shaft out. Note: When pressing axle shaft out ensure sufficient clearance is available. - Pull wheel bearing housing with ball joint out from control arm. - Remove axle shaft from wheel bearing housing and tie up. - The axle shaft must not hang down! - The inner CV joint will be damaged through overflexing. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove cover plate. - Remove connecting link from control arm. - Release speed sensor wiring from suspension strut. Caution: Place engine/transmission jack V.A.G. 1383/A underneath (danger of accident from falling parts when removing the wheel hub and the wheel bearing). Pulling out wheel hub - Insert thrust bolts -1 - in wheel bearing housing. - Install support - 2 - piston cylinder - 3 - with pull rod and special nut - 4 - . - Hold tool firmly pull out wheel hub. Locations Multiple Junction Connector: Locations A Pillar Coupling Station Driver's side The coupling station is located in the front left footwell behind the footwell trim. 1 - Central locking 2 - Electric windows, red 3 - Electric mirror adjustment, blue NOTE: Allocation of the coupling station on the front passenger side A pillar is a mirror image! Page 2778 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 1777 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid Capacity ............................................................................................................................................... .................. 0.7 to 0.9 liter (0.74 to 0.95 quarts) Hydraulic Oil ........................................................................................................................................ ...................................... part number G 002 000 Note: Do not use ATF Page 1210 - Spray the sensor (arrow) with commercially available chilling spray and watch the temperature value. The temperature should decrease. - End diagnosis and switch ignition off. If the intake air temperature does not drop: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Continuation of test if indication is approx. -40 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Bridge terminals 1 + 3 of connector using the respective adapter cables while observing the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. Page 3143 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6437 - Remove shock absorber bolt -1- on rear axle. NOTE: For ease of illustration work sequence is shown without wheel. - Remove shock absorber. - Install in reverse sequence Tightening torque: Shock absorber to rear axle 60 Nm (44 ft. lbs.) Use new nuts! Load rear of vehicle with one person when tightening Shock absorber to body 75 Nm (55 ft. lbs.) Use new bolts! Shock Absorbers Vehicles With FWD, Assembly Overview 1. Gas-filled shock absorber ^ Can be replaced individually Replacement parts catalog ^ Checking shock absorber for leaks and noises Special Information Suspension Wheels Steering No. 3 ^ Disposal: observe environmental regulations Functional check Press shock absorber together by hand. Piston rod must move over its complete length smoothly with even force. When shock absorber has sufficient gas pressure piston rod returns to its original starting Position. Page 6535 Installing Replacement flap motors are supplied in the "recirculating air" position. To ease the installation, first do the following: - Connect electrical connector -1- to flap motor -2-. - Switch on ignition. - Operate button for fresh air/recirculating air. When the center position has been reached: - Disconnect electrical connector -1- from flap motor -2-. - Insert flap motor in fresh air/recirculating air shaft -1-. If the flap motor cannot be attached to the fresh air/recirculating air flap shaft -1-, remove fresh air blower -V2- and attach flap by hand. - Turn flap motor in direction of -arrow A- and tighten bolts. - Attach operating rod for air flow flap. - Initiate Basic setting, function 04 See Climatronic, OBD. Central flap motor -V70-, removing and installing First do the following: - Remove glove box. - Remove trim under the steering column. - Remove center console. - Remove connecting duct. Removing Page 5096 Test Step 7 - 15 Page 5014 Fig. 3 Removing bearing inner race Note: When removing and installing the inner races do not bend selector forks. Fig. 4 Pressing inner race in onto stop Fig. 5 Selector fork with selector segments installed Selector segment assignment refer to Fig. 1. Page 6367 Steering Wheel: Removal and Replacement Steering Wheel - Assembly Overview Steering Wheel - Assembly Overview 1 - Steering wheel 2 - Socket-head bolt 55 Nm - coated with locking compound - may be used up to five times - press in a punch indentation after each installation 3 - Torx bolts 5 Nm 4 - Airbag unit with driver side airbag igniter -N95- Because of differing engaging mechanisms, only steering wheels and airbag units from same supplier can be installed. - Removing, three-spoke steering wheel - Removing, four-spoke steering wheel 5 - Connector 6 - Securing plate Steering Wheel - Removing and Installing STEERING WHEEL, REMOVING AND INSTALLING Removing - Remove driver side airbag unit. - Turn steering wheel - 1 - to center position (wheels in straight-ahead position). Page 4175 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant 40 - Multi-Function TR Switch -F125- (pin 2) Page 6481 Page 5683 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 306 Owner Letter Page 5448 Lateral Accelerometer: Locations ESP-Sensor Unit (Vehicles With ESP) G419 - ESP-Sensor Unit (vehicles with ESP) Page 2880 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 3603 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin harness connector to Motronic Engine Control Module (ECM) according to wiring diagram. Terminal -3- + socket 68 - Terminal -4- + socket 69 Wire resistance: max. 1.5 ohms - Check wiring at harness connector terminals -3- + -4- for short circuit to terminals -1- + -2according to wiring diagram. Specified value: infinity ohms If no wiring fault is detected: - If no malfunction is found in the wiring, replace Engine Control Module (ECM). Heater Check Heated Oxygen Sensor (HO2S) After Three Way Catalytic Converter (TWC), Checking Special tools and equipment - VAG1551 Scan Tool (ST) Or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements Service and Repair Output Shaft: Service and Repair For further information regarding this components and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Locations Air Bag Control Module: Locations J234 - Airbag control module Fuse Arrangements In Fuse Holder, Instrument Panel Left Fuse: Application and ID Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 1186 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Page 3745 - Disconnect pressure hose to combination valve at coupling (arrow) and blow into it with light pressure. Combination valve must close. NOTE: To disengage, compress the buttons at the hose coupling. - Operate vacuum pump. Combination valve must open. If the combination valve does not open or it is constantly open: - Replace combination valve. Page 4286 ^ For any repair requested by the owner under warranty or outside warranty that requires flashing, which will automatically wipe out the "Tuning" program, your Dealership should advise the owner of the above and get Owner's written consent (see Control Module Tuning form) to the flashing procedure. Tool requirements ^ VAS 5051 or 5052 (with Basis CD V.07.00.00 and the Brand CD V.07.54.00 or higher) with old diagnosis logs erased prior to start. ^ "Update - Programming" (flashing) CD W42MILP0134. Note: Additional copies of the "Update - Programming" CD (Literature Number W42M1LP0134) may be ordered from the Volkswagen Technical Literature Ordering Center. Vehicle requirements ^ Battery MUST have minimum n0-load charge of 12.5V (failure to maintain voltage during update process can lead to ECM failure) (it is advised to use an approved battery charger to maintain battery voltage). ^ VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure. ^ VAS 5052: connected to vehicle with battery voltage requirements met. ^ Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF. ^ No Stored DTC's, erase any stored DTCs (see CAUTION under Procedure). CAUTION! Non-observance of the following points may lead to ECM failure! VAS 5051 or 5052 must always be connected to the approved power supply at the approved voltages. Under no circumstances should the power supply be interrupted or the diagnostic connector unplugged during the flash procedure. Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF "Update - Programming" (flashing) procedure, checking for update match - Switch ignition ON. - Switch VAS 5051/5052 ON and insert flash CD into CD drive as soon as start screen appears. NOTE: You must return to the start screen before starting a new (flashing) session, otherwise the flashing CD will not be recognized by the tester - Select "Vehicle Self Diagnosis" mode. - Select vehicle system "01-Engine electronics". ^ Program checks software level. ^ If software level of ECM MATCHES level indicated by Flashing CD: ^ "Update - Programming" (arrow) will not appear. Note: The "Update - Programming" function is only available when the inserted flashing CD level and current vehicle ECM level are different If "Update - Programming" does not appear: - Programming (flashing ECM cannot be performed, continue to diagnose condition. If software level DOES NOT match the level indicated on Flashing CD: ^ "Update - Programming" (arrow) appears. PRIOR to performing procedure to "Update - Programming" (flash) the ECM: Page 1897 1. Axle shaft ^ For special model "Golf GTI 132 kW" ^ Pulling axle shaft out from wheel hub and pressing in 2. Axle shaft ^ Pulling axle shaft out from wheel hub and pressing in 3. Speed sensor 4. Hex socket head bolt, 10 Nm (89 in lb) 5. Suspension strut 6. Hex bolt ^ Always replace ^ The point on the hex bolt must point in normal direction of travel 7. Tie rod end 8. Self-locking nut ^ 60 Nm (44.2 ft lb) plus an additional 90° - 1/4 turn ^ Never less then 90°! ^ Turning angle tolerance 90 to 120° ^ Always replace 9. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 10. Wheel bearing housing For vehicles: ^ With gasoline engines up to and including 92 kW(123 Hp) ^ With SDI/TDI engine Page 2869 - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 6,4...47,5 Ohm (at room temperature) If specified value is not obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-: Vehicles with engine code AFP, item 9. - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1706 Indicated on display - Press keys 0, O, and 5 to select the Display group number 005. - Confirm entry with key Q. Indicated on display The first display zone shows the ATF temperature. - Bring ATF to test temperature. Test temperature: 35°C to 45°C - Raise vehicle. - Place container under transmission. - Remove ATF level plug from transmission oil pan. The ATF present in the overflow pipe (arrow 2) runs out. - Observe amount of ATF draining from plug hole afterward. If ATF drips out of the hole: ATF need not be topped up. Install new seal (arrow 1) to plug and tighten to 15 Nm, ATF check is completed. Page 1704 - Connect diagnostic cable connector to Data Link Connector (DLC). - Switch on tester-arrow-. Note: The tester requires approx. 3 minutes to warm up. - Start engine. - Select zone "Vehicle self-diagnosis" on touch screen. - From this point, tester VAS 5051 guides user further. If V.A.G 1551 is used: - Remove DLC cover -1-. - With ignition switched off, connect V.A.G 1551 Scan Tool with diagnosis cable V.A.G 1551/3A. Page 551 If specified value is obtained (wires have no shorts): - Eliminate error in wires (see wiring diagram). Page 1265 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -3- and -4(harness connector to Engine Control Module (ECM)). - Start engine and run at idle. - Measure voltage supply and observe display group 41, display field 2. Display: Htg.bC.ON Specified value: 11.0-14.5 V Display: Htg. bC.ON/Htg.bC.OFF (alternating) Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Keyless Entry/Starting - Remote Key Inoperative Keyless Start Transmitter: All Technical Service Bulletins Keyless Entry/Starting - Remote Key Inoperative 57 08 10 Oct. 28, 2008 2011385 Supersedes T.B. Group 57 number 08-08 dated May 20, 2008 due to addition of 2009 CC. Vehicle Information Condition Remote Control Key Diagnostics ^ Remote control key is inoperative, or has inconsistent operation. ^ Only Lock button on remote control key functional ^ DTC 00956 005, No or Incorrect Basic Settings/Adaptation may be present. Technical Background Proper diagnosis of remote control key functionality is critical before replacement of remote. Production Solution No production change required. Service Brakes - Master Cylinder/ABS Pressure Testing Adapter Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - Master Cylinder/ABS Pressure Testing Adapter Condition Master Cylinder / ABS, Adaptor for Checking Pressure Pressure adaptor VAG 1310/26 allows the use of VAG 1310 A to check for hydraulic pressure loss at either the master cylinder or ABS control unit. Before replacing the ABS unit due to an incorrect pressure reading when performing Leak Test, check brake fluid pressure at the master cylinder and ABS unit as follows: 47 06 01 Aug. 28, 2006 2002320 Supersedes T.B. Group 47 number 01-01 dated January 4, 2001 due to updated information. Technical Background Introduction of adaptor to allow pressure testing of brake hydraulic system. Production Solution No production change required. Service Pressure Leak Test Obtain special tools: - VAG 1310/26 Pressure Adaptor - VAG 1310 A Brake Pressure Gauge Use VAG 1310/26 with VAG 1310 A to measure hydraulic brake pressure at master cylinder and ABS unit as follows: - Remove brake lines at either master cylinder port (A or B). Install VAG 1310/26 at port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". Brake fluid pressure can also be checked at the ABS unit: - Disconnect brake lines from ABS unit to disc brake calipers (1-4), one at a time. Page 2587 Indicated on display (1-4 "display fields) - Press brake pedal and hold. Note: The engine control unit will increase the engine speed. - Check specifications in fields 1-4. If the diagnosis was started by the engine control unit, the field 4 will jump from "Test OFF" to "Test ON." Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 2588 Display Fields - Press - button. - Check DTC memory. - Read readiness code. - If fault memory has been erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. If the indictor behaved as described: Release brake pedal. - Press C button. Diagnosis of catalytic converter Note: This diagnosis will only exit if the diagnosis of the aging of the oxygen sensors has already been completed successfully. Indicated on display Press "0", "4" and "6" for display group 46 and acknowledge with "Q." Page 4957 6500-17 - 17mm Allen Socket 6500 X-30 - 30mm, 12-Pt. Socket Page 1925 6500-17 - 17mm Allen Socket 6500 X-30 - 30mm, 12-Pt. Socket Page 6085 malfunctioning electrical consumers, corrosion due to water ingress etc. - All shielded wiring (eg.: knock sensors, antenna etc.) are Not to be repaired! Replace complete wiring harnesses as necessary. - When repairing airbag wiring harnesses, use only prescribed terminals, connectors and wiring. - Only the yellow repair cables and insulation tape supplied with VAS 1978 are to be used for wiring/connector repairs. The use of yellow repair wires and yellow insulation tape identifies that a repair has taken place! - When repairs are completed, always perform a functional check of the component or system. Where applicable, check and erase Diagnostic Trouble Codes (DTCs) and set basic setting. - Additional information on removal and installation of electrical and related components. Page 3169 Display Group 062 - Depress accelerator slowly until Wide Open Throttle (WOT) position and observe angles displayed in display fields 1 and 2. The percentage displayed in display field 1 must rise continuously and evenly. The full tolerance range (3-93%) is not always displayed. The percentage displayed in display field 2 must fall continuously and evenly. The full tolerance range (97-3%) is not always displayed. NOTE: - The display in display field 1 rises and the display in display field 2 falls because the potentiometers (angle sensors) in the throttle valve control modules run in opposite directions. - This means that the voltage of one angle sensor moves toward 5 volts (the more the throttle valve is opened the higher the voltage; percentage increases), while the voltage of angle sensor 2 drops from 5 volts toward 0 volts (the more the throttle valve is opened the lower the voltage; percentage falls). If the specified values are obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 3414 Display Group 062 - Depress accelerator slowly until Wide Open Throttle (WOT) position and observe angles displayed in display fields 1 and 2. The percentage displayed in display field 1 must rise continuously and evenly. The full tolerance range (3-93%) is not always displayed. The percentage displayed in display field 2 must fall continuously and evenly. The full tolerance range (97-3%) is not always displayed. NOTE: - The display in display field 1 rises and the display in display field 2 falls because the potentiometers (angle sensors) in the throttle valve control modules run in opposite directions. - This means that the voltage of one angle sensor moves toward 5 volts (the more the throttle valve is opened the higher the voltage; percentage increases), while the voltage of angle sensor 2 drops from 5 volts toward 0 volts (the more the throttle valve is opened the lower the voltage; percentage falls). If the specified values are obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 2216 - Remove bolts to timing chain lower guard rail dark - arrows - Remove timing chain lower guard rail. Installation Page 3381 - Check resistance for sensor heater at connector to oxygen sensor terminal 3 + 4. - Specified value: 2.5...10.0 Ohm (at room temperature) If specified value is not obtained: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7. - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 4 + socket 5 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 6-pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2275 - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Vehicles with engine code BDF - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. Page 3611 Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control Before TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (Before Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair contacts 3 and 4 in the oxygen sensors harness connectors. Special tools and equipment - VAG1551/VAG1552 with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - Min. coolant temp. 85 °C See display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -3- and -0- to input display group number 30 and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 Page 3361 Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control Before TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (Before Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair contacts 3 and 4 in the oxygen sensors harness connectors. Special tools and equipment - VAG1551/VAG1552 with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - Min. coolant temp. 85 °C See display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -3- and -0- to input display group number 30 and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 Page 2534 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1377 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Powertrain Page 282 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 6272 Power Steering Pump: Service and Repair Power Steering Pump (Pump In Upper Area), Remove and Install Power steering pump is not serviceable. If malfunction in pump is suspected, determine cause using pressure and leak tests; if malfunctioning replace complete unit NOTE: ^ Pumps supplied as replacement parts are not filled with oil. Fill pump with hydraulic oil Part No. G 002 000 and rotate by hand, otherwise pump may be damaged or noisy during operation. ^ Type of oil: hydraulic oil Part No. G 002 000 ^ Oil system capacity: 0. 7 - 0. 9 ltr. (11. 815.2 oz.). Removing - Remove noise insulation. - Loosen belt pulley hex bolt. Counter-hold with a hex key if necessary. Page 5650 ^ Pull parking brake cable out of guide tube -1- in direction of arrow. Installing ^ Slide parking brake cable into guide tube. ^ Press brake lever -2- in direction of arrow and attach parking brake cable. ^ Install clip -1-. ^ Clip parking brake cable into retainer on rear axle (arrow -A-). Parking brake cable clamp ring must lie in middle of clip. ^ Hook parking brake cable into retainers (arrows). ^ Hook parking brake cable into compensator. Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) switch Page 5413 - Install VAG 1310/26 at each port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". NOTE: Once the brake pressure leak test has been completed, the hydraulic brake system MUST be purged of any entrained air. See Repair Manual Group 47, Brake System Bleeding. Warranty Information only. Required Parts and Tools No Special Parts required. Always see ETKA for the latest part(s) information. Page 4929 1. Axle shaft ^ For special model "Golf GTI 132 kW" ^ Pulling axle shaft out from wheel hub and pressing in 2. Axle shaft ^ Pulling axle shaft out from wheel hub and pressing in 3. Speed sensor 4. Hex socket head bolt, 10 Nm (89 in lb) 5. Suspension strut 6. Hex bolt ^ Always replace ^ The point on the hex bolt must point in normal direction of travel 7. Tie rod end 8. Self-locking nut ^ 60 Nm (44.2 ft lb) plus an additional 90° - 1/4 turn ^ Never less then 90°! ^ Turning angle tolerance 90 to 120° ^ Always replace 9. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 10. Wheel bearing housing For vehicles: ^ With gasoline engines up to and including 92 kW(123 Hp) ^ With SDI/TDI engine Page 4779 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations F18 - Coolant Fan Control (FC) thermal switch Page 5730 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 5127 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Service and Repair Power Steering Line/Hose: Service and Repair For information regarding this component and the system that it is a part of, please refer to Power Steering Pump. Page 3102 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Capacity Specifications Fluid - M/T: Capacity Specifications 02J Manual Transmission Transmission fluid Capacity ................................................................................................................. ................................................................................................... 2.0 liters 02M Manual Transmission Transmission fluid Capacity ................................................................................................................. ................................................................................................... 2.3 liters Page 2376 ^ Remove pin (brown/white wire) from cavity 9 (black arrow) of this connector. ^ Cut connector from brown/white wire removed from cavity 9, then, fold loose wire end back to harness and secure with vinyl tape (see above - Unused wiring, taping back to harness). ^ Insert terminal / wire (5 cm) previously removed (see above - Engine overlay harness, preparation) from engine overlay harness into cavity 9. ^ Reattach single wire portion of engine overlay harness (previously removed) to pin 9 of (10 or 14 pin) connector using wire splice Part No: 111971941A (shorten wire to achieve correct length). ^ Reconnect connector. ^ Continue harness routing down cable channel. then loop behind channel and route to bulkhead. ^ Reinstall cable channel cover. ^ Push guide tube through main harness (arrow) into vehicle interior at bulkhead. From inside vehicle, behind relay panel: ^ Pull guide tube with overlay harness inside vehicle. ^ Continue routing two wire portion of engine overlay harness along main harness towards instrument cluster following original harness route along cross member (DO NOT secure with tape at this time). ^ Remove guide tube from harness. Service and Repair Valve Guide Seal: Service and Repair Valve stem seals, replacing (Cylinder head installed) Special tools, equipment, test and inspection devices; required accessories Special Tools - Mounting device 2036 - Extruder 3047 A - Spark plug wrench 3122B - Press down device 3129 - Mounting lever VW 541/1A - Thrust piece VW 541/5 - Flexible pressure tubing VW 653/3 Removing Remove camshafts. - Remove valve lifters (do not mix up) and place aside with the running face facing down. - Remove spark plugs with spark plug wrench 3122 B. - Bring the piston of each applicable cylinder into the "Bottom Dead Center" (BDC) position. Page 6352 06 End output - Press -Q- button to confirm input. Indicated on display: Rapid data transfer Help Enter address word XX - Switch off ignition. - Disconnect VAG 1551 Scan Tool (ST). Without Manufacturer Scan Tool The manufacturer does not provide a procedure for clearing diagnostic trouble codes without a scan tool. Description of On-Board Diagnostics Multi-function Steering Wheel, On Board Diagnostic (OBD) General information The multi-function steering wheel allows the various functions of the radio and cruise control system to be selected from the steering wheel. The multi-function steering wheel is comprised of the following components: - The operating unit in steering wheel with two sets of buttons on left and right integrated electronics. - The control module for the multi-function steering wheel. Before troubleshooting or servicing, technicians must be familiar with the functions and operation specifics of the applicable standard or optional radio system and cruise control system as controlled by the multi-function steering wheel. Always read the vehicle/radio owner's manual and review all radio, tape player and CD changer functions. The On Board Diagnostic (OBD) must be initiated at the commencement of troubleshooting and the stored information checked with the VAG 1551/1552 scan tool or VAS 5051 Vehicle Diagnostic, Testing and Information system. NOTE: The following description and illustrations deal specifically with the VAG 1551 scan tool. VAG 1552 and VAS 5051 procedures are similar. List of available functions Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 1403 - Switch on ignition. - Close doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. NOTE: If engine Electronic Control Module (ECM) is subject to low voltage with ignition on, DTC memory and Readiness code must be checked Page 4416 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 3264 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6091 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1518 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 339 Radiator Cooling Fan Control Module: Connector Views Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 1999) Page 1453 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5236 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant 40 - Multi-Function TR Switch -F125- (pin 2) Page 4686 - Install central console. - Install selector lever handle. - Install left-hand trim under instrument. - Install steering column trim. - Install handle for steering column height and reach adjustment. - Install steering wheel and air bag. - Reconnect Ground strap to battery. - Enter radio code. Page 5133 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 5871 Battery: Service and Repair Battery (With Clip Secured Fuse Holder) Battery (with Clip Secured Fuse Holder), Removing And Installing CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Special tools, testers and auxiliary items needed - VAG 1331 Torque wrench (or equivalent 5 - 50 Nm) Battery, removing First remove battery cover and fuse holder from battery: - Switch off ignition. - Unclip battery positive cable from retainer -1- Press locking lugs together -2- and remove battery cover. CAUTION! Do not loosen or remove ground strap from body. Disconnect from battery only. - Disconnect battery Ground (GND) strap from battery negative post. Page 2627 Part 1 Page 4405 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Page 5651 ^ Pretension parking brake cable with adjustment nut (arrow). ^ Adjusting parking brake. ^ Install center console extension. Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Page 4265 ^ For any repair requested by the owner under warranty or outside warranty that requires flashing, which will automatically wipe out the "Tuning" program, your Dealership should advise the owner of the above and get Owner's written consent (see Control Module Tuning form) to the flashing procedure. Tool requirements ^ VAS 5051 or 5052 (with Basis CD V.07.00.00 and the Brand CD V.07.54.00 or higher) with old diagnosis logs erased prior to start. ^ "Update - Programming" (flashing) CD W42MILP0134. Note: Additional copies of the "Update - Programming" CD (Literature Number W42M1LP0134) may be ordered from the Volkswagen Technical Literature Ordering Center. Vehicle requirements ^ Battery MUST have minimum n0-load charge of 12.5V (failure to maintain voltage during update process can lead to ECM failure) (it is advised to use an approved battery charger to maintain battery voltage). ^ VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure. ^ VAS 5052: connected to vehicle with battery voltage requirements met. ^ Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF. ^ No Stored DTC's, erase any stored DTCs (see CAUTION under Procedure). CAUTION! Non-observance of the following points may lead to ECM failure! VAS 5051 or 5052 must always be connected to the approved power supply at the approved voltages. Under no circumstances should the power supply be interrupted or the diagnostic connector unplugged during the flash procedure. Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF "Update - Programming" (flashing) procedure, checking for update match - Switch ignition ON. - Switch VAS 5051/5052 ON and insert flash CD into CD drive as soon as start screen appears. NOTE: You must return to the start screen before starting a new (flashing) session, otherwise the flashing CD will not be recognized by the tester - Select "Vehicle Self Diagnosis" mode. - Select vehicle system "01-Engine electronics". ^ Program checks software level. ^ If software level of ECM MATCHES level indicated by Flashing CD: ^ "Update - Programming" (arrow) will not appear. Note: The "Update - Programming" function is only available when the inserted flashing CD level and current vehicle ECM level are different If "Update - Programming" does not appear: - Programming (flashing ECM cannot be performed, continue to diagnose condition. If software level DOES NOT match the level indicated on Flashing CD: ^ "Update - Programming" (arrow) appears. PRIOR to performing procedure to "Update - Programming" (flash) the ECM: Page 6383 - Unclip brake cable (arrows). - Remove clips -2- both sides. - Remove bolts -1- on rear axle bearing bracket, both sides. - Position a wooden block approx. 100 mm (3.34 in.) long between rear axle and body. - Position VW 771 slide hammer and pull out bonded rubber bushing Installing Bonded rubber bushing has mark -1- on face. Mark must align with edge (arrow) on trailing arm -2-. Mark position of mark -1- on bonded rubber bushing. Service and Repair Turn Signal Switch: Service and Repair Steering Column Switch/ Combination Switch/ Turn Signal Switch Special tools and workshop equipment required - Torque Wrench -V.A.G 1331WARNING! Always follow the instructions regarding disconnecting and connecting the battery. Removing - Disconnect the battery. Please refer to See: Starting and Charging/Battery/Service and Repair - Remove driver's airbag. Please refer to See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair - Remove the steering wheel. Please refer to See: Steering and Suspension/Steering/Steering Wheel/Service and Repair - Remove the return ring with slip ring. Please refer to See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair - Disconnect the connectors from the steering column switch. - Loosen the clamping bolt of the steering columns switch -arrow- and pull the steering column switch rearward and off from the steering column. Installing - Install in reverse order of removal. Service and Repair Shift Fork: Service and Repair 5 Speed Manual 02J Selector forks, disassembling and assembling Special tools and equipment - 10-206 Drift - VW 431 Press piece - VW 402 Thrust plate - VW 408 A Press tool - VW 472/2 Spacer sleeve Page 2085 states: Ignition ON, engine stopped, oil pressure switch closed - Engine speed above 1500/min, oil pressure switch open Note: The indicator light is not switched off if the engine speed exceeds 5000 rpm, not even if the oil pressure switch is closed. The indicator light will be shut off again when the engine speed drops below 5000 rpm. - If the oil pressure switch is only opened for 0.5 - 3.0 seconds when the engine speed is over 1500 rpm, this fact will be stored in the instrument cluster processor. If this state occurs three times while the engine is running, the warning will be triggered and will not be cleared even under 500 rpm. The warning will be cleared when the oil pressure switch is closed for more than 5 seconds and the ignition is turned off Test conditions - Oil level OK. - Indicator lamp for oil pressure (K3) must illuminate for approx. 3 seconds after the ignition is turned on. - Oil temperature at least 80°C Oil pressure switch, checking - Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw it into tester. - Screw tester into oil filter housing in place of oil pressure switch. - Ground tester brown lead (-). - Connect VAG 1527 B diode test lamp to battery positive terminal (+) and to oil pressure switch using the auxiliary cables from VAG 1594 A. Light-emitting diode (LED) should not illuminate. If the LED illuminates: Replace 1.4 bar oil pressure switch (F1) If the LED does not illuminate: Start engine and let idle. Light-emitting diode should light at 1.2 - 1.6 bar. Otherwise, replace 1.4 bar oil pressure switch F1). Oil pressure, checking Test condition - The VAG 1342 oil pressure test instrument is not connected - Oil temperature at least 80 0 C Test sequence - Start engine and let it idle. Specification: oil pressure: at least 2.0 bar Increase engine speed. The oil should be at least 2.0 bar at 2000 rpm and 80° C oil temperature. - The oil pressure may not exceed 7.0 bar - Replace oil pump if necessary. Page 1712 - Pry off plug securing cap -arrow- with a screwdriver. Cap locking device will be destroyed. Always replace cap. - Pull plug out of filler pipe. - Fill with ATF using V.A.G 1924 until ATF runs out of inspection hole. If ATF needs to be topped up, then only ATF with Part No. G 052 990 A2 may be used. Note: An insufficient ATF filling as well as filling to excess affects the function of the transmission. - Fit plug on filler pipe and secure with a new cap -arrow-. - Lock cap. Page 5645 ^ Disconnect wiring connectors from pressure sensors -a- and -b-. All vehicles ^ Disconnect brake lines at brake master cylinder and seal with plugs from repair kit, Part No. 1H0698311 A. ^ Remove nuts securing brake master cylinder to brake booster. ^ Remove heat shield if installed. ^ Carefully remove brake master cylinder from brake booster. Installing ^ Install master cylinder in reverse order of removal. Observe the following points when installing: ^ When connecting brake master cylinder and brake booster, be sure that push rod is correctly located in brake master cylinder. ^ After installing, bleed brakes. ^ Restore basic setting. Specifications Brake Fluid: Specifications Brake Fluid Type Use only brake fluid that meets SAE specifications J 1703 and conforms to Federal Motor Vehicle Standards 116. DOT 4 Page 4428 Data Link Connector, A/T: Locations 5 Speed Automatic 09A Data Link Connector (DLC) location The DLC -arrow- is located under the instrument panel to the left of the steering column. Page 6182 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 1498 Part 1 Page 2269 Fuel Pressure: Specifications Residual Pressure After 10 minutes there must be a residual pressure of at least ................................................................................................................................ 2.0 bar. Locations Neutral Start Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2854 Display Group 032 Initiating learning process: Control module in Basic Setting scan tool function 04. Learning prerequisites for idle speed: - Idle speed - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C Page 3306 Display Group 126 Evaluating Display Group 125 Evaluating Display Group 125 Intake Air Temperature Sensor - Climate Control Ambient Temperature Sensor / Switch HVAC: Description and Operation Intake Air Temperature Sensor - Climate Control Fresh air intake duct temperature sensor -G89Function: Temperature sensor controls temperature flap and fresh air blower depending on temperature. In event of malfunction: outside temperature sensor -G17- value is used instead. Page 2819 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Locations Backup Lamp Switch: Locations F4 - Back-up light switch Locations Radiator: Locations Cooling system components, body side Main radiator 1. Radiator 2. O-Ring 3. Upper coolant hose 4. Air scoop 5. 10Nm 6. Coolant fan (V7) 7. Fan bracket 8. Retaining clamp 9. Connector 10. Coolant fan (V35) 11. Bracket for fan connector 12. Lower coolant hose 13. O-Ring 14. Thermo switch (F18), 35 Nm for electric fan 15. Bracket for radiator 16. 15 Nm Locations Manifold Pressure/Vacuum Sensor: Locations G71 - Manifold Absolute Pressure (MAP) sensor Page 524 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 1520 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 3862 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 484 - Use wiring diagram to check cables between test box and connector for any broken connections. Contact 1 + cavity 72 - Contact 2 + cavity 73 - Contact 3 + cavity 36 - Contact 4 + jack 35 - Contact 5 + jack 33 - Contact 6 + jack 34 - Line resistance: max. 1.5 Ohms - Also check cables for a short circuit to battery positive terminal or to ground. - Also check cables for short circuits between each other. If no problems can be found in the cables: - Replace throttle position sensor (G79), item -4-. Page 2517 also transmitted to the Motronic Engine Control Module (ECM). Confirm G65 circuit using wiring diagram. - On vehicles where G65 is NOT connected to the ECM, connect green clip from VAG 1767 directly to G65 pin 2 using appropriate VAG 1594 adapter cable - 7 - . Proceed directly to checking. - Disconnect engine harness electrical connection from Engine Control Module (ECM) - 3 - . - Locate correct test box VAG 1598A - 4 - and adapter according to pin assignments of ECM - 3 and connect test box to engine wiring connector/harness - 2 - . - Connect black clip from VAG 1767 to Ground (GND) - 5 - . - Determine applicable G65 signal input pin assignment to ECM using wiring diagram. Example: T121/61 Note: As G65 function primarily controls coolant fan and A/C clutch operation, the engine wiring diagrams may indicate the G65 signal connection as being "Coolant fan control module connection" . - ECM terminal number assignments correspond with those on test box VAG 1598A . - Connect green clip from VAG 1767 to the corresponding numbered position on test box VAG 1598A connected to G65 pin - 2 - using appropriate VAG 1594 adapter cable - 7 - . Example: 61 Checking Switch ignition on. - Press button - arrow - for Duty Cycle measurement (modulation ratio) on ignition tester VAG 1767 (or select same function on equivalent device). Evaluating results Note: If a malfunction cannot be located, check DTC memory of Engine Control Module (ECM) and the Transmission Control Module (TCM) using VAG 1551/1552/1552 . When doing so, note that DTCs related to sensor G65 functions may be called-out as "A/C pressure switch -F129-" . Page 2916 - Carry out road test with 2nd person to observe display. Observe safety precautions when carrying out road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions - Observe figure displayed in display field 3: Specified value: approx. driven speed Display Group 005 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If no speed is displayed: - Remove wiper arms and plenum chamber cover. Page 5815 Tip: Label shown is for example only. DIN or SAE specifications may vary from battery to battery. Tip: Two 6-volt batteries are connected in series to achieve 12-volts, the same current value will flow through each battery. As a result, only use a DIN value of 380A, DO NOT double or halve this value when entering data into Midtronics tester. If DIN rating is not shown: ^ Use SAE value as printed on battery label. If using SAE value rating: ^ Midtronics tester menu option must be changed to achieve accurate results. ^ A change from DIN to SAE can be made from the "Other" menu option on Midtronics tester. When testing or charging battery installed in vehicle: ^ DO NOT Test/Charge from Remote Location (3.2L). ^ (3.2L) DO NOT use remote location (+) -arrow-. ^ (3.2L) DO NOT use engine bracket (-) -arrow-. Page 6216 Vehicle data label is located in the following locations: - Vehicles up to 03.00: In spare wheel recess - Vehicles from 04.00 (Only Jetta vehicles): Next to spare tire wheel well, near left rear wheelhouse - In service booklet Page 427 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Fuel Delivery, Checking Fuel Pressure: Testing and Inspection Fuel Delivery, Checking Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. With Generic Scan Tool Checking Fuel Delivery Test requirements - Voltage supply OK - VAG1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect supply line -3- (with white marking) and catch escaping fuel using a rag. NOTE: Depress buttons on hose connections to do so. WARNING: - The fuel or fuel lines in fuel system can become very hot (danger of scalding). - In addition, the fuel system is under pressure!Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection. - Wear protective goggles and protective gloves when working on the fuel system. - Connect pressure gauge (VAG1318) to fuel supply line using adapters (VAG1318/23 and VAG1318/17). - Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. Page 2582 Warranty Required Parts and Tools When replacing any catalyst, your VIN may be required to ensure the correct part is ordered (check with your parts department). No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 6584 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temperature Switch Ambient temperature switch -F38- Switches off A/C clutch -N25- at low outside temperatures. - Off at -1 °C (30 °F). - On at +7 °C (45 °F). Page 2773 Wire resistance: max: 1.5 Ohm Continuation for all vehicles - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Right Rear ABS Wheel Speed Sensor Wheel Speed Sensor: Locations Right Rear ABS Wheel Speed Sensor G44 - Right Rear ABS Wheel Speed Sensor Page 546 Engine Control Module: Locations J220 - Motronic Engine Control Module (ECM) J220 - Motronic Engine Control Module (ECM) - in plenum, center - for gasoline engine with motronic MFI Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Camshaft Seal Extractor - AST Tool # 3240 Camshaft: Tools and Equipment Camshaft Seal Extractor - AST Tool # 3240 Camshaft Seal Extractor AST tool# 3240 Used to remove the left and right front camshaft oil seals. Applicable to: Audi 2.7L & 2.8L v6 engines. - Made in Germany - Contact AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 6353 Indicated on display (select function): Rapid data transfer HELP Select function XX With Manufacturer Scan Tool Diagnostic Trouble Code (DTC) Memory, Checking (Function 02) NOTE: DTCs stored in memory along with corresponding malfunction descriptions can only be displayed by initiating the On Board Diagnostic program and checking DTC memory (function 02). - Connect VAG 1551 Scan Tool (ST), input address word 16, "Steering wheel electronics", and press button until "Select function XX" appears in display. - Switch on printer with the Print button (indicator lamp in button lights up). Page 3073 Body Control Module: Locations J393 - Central Control Module For Comfort System J393 - Central control module for comfort system Page 1969 Camshaft: Tools and Equipment Camshaft Alignment Tool - AST Tool # 3391 Camshaft Alignment Tool AST tool# 3391 Used to hold both camshafts in T.D.C. position. Applicable to VW and Audi V6, 2.8L and 2.7L engines with 5 valves per cylinder. Used in conjunction with 3242. For the 3.0 V6 used in Audi models see #T 40030 - Used for Camshaft Alignment - Applicable to VW and Audi - Used in conjunction with #3242 - Made in U.S.A. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: 4 Speed Automatic 01M Shift Interlock Solenoid: Service and Repair 4 Speed Automatic 01M Shift lock solenoid -N110-, removing and installing Removing Obtain radio code on vehicles with coded radio. - Disconnect battery Ground strap. - Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7 and remove. Note contact spring for selector lever position display! - Remove locking segment (2 bolts). - Place selector lever in position "1". - Remove retaining bracket -8- (2 nuts). - Remove solenoid securing bolts -9- (Qty. 2) - Remove front selector mechanism securing nuts (Qty. 2). - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. Note: Do not bend or kink the selector lever cable. Page 3679 If indicated voltage does not oscillate: - Remove instrument cluster: - Check wire connection from Engine Control Module (ECM) to Speedometer -G21- according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 111 Vehicle Information Sunroof and Central Control Module -J393- Diagnosis Technical Background Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof being interrupted while in operation, or a faulty central control module. Production Solution No production change required. Service Symptoms Sunroof inoperative. Sunroof will not close (stuck open or stuck open in the tilt position). Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position). Warranty When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Ribbed Belt Pulley With Freewheel, Removing and Installing Alternator Pulley: Service and Repair Ribbed Belt Pulley With Freewheel, Removing and Installing Ribbed Belt Pulley With Freewheel, Removing And Installing Installing ribbed ribbed belt pulley with freewheel Special tools, testers, measuring instruments and auxiliary items required - VAG 1332 Torque wrench (40 - 200 Nm) - 3400 Multi-spline adapter - First remove existing ribbed belt pulley. - Insert multi-spline adapter 3400 in freewheel disc. - Screw freewheel disc by hand onto generator drive shaft onto stop. The torque wrench must be rearranged before installing the freewheel disc as follows: With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 4987 Warranty Required Parts and Tools 4 Speed Automatic 01M Valve Body: Service and Repair 4 Speed Automatic 01M Valve body, removing and installing Special tools and equipment - 3373 Lever for conductor strip - V.A.G 1331 Torque wrench WARNING: Do not run the engine or tow the vehicle with the oil pan removed or when there is no ATF in the transmission. Note: The valve body or the conductor strip can also be removed when the transmission is installed. The conductor strip can be removed individually. After reinstalling the Oil pan, fill with ATF. Always replace a valve body, which is faulty. Page 4111 Spark Plug: Tools and Equipment Plug Connector Remover - AST Tool # H 1849-6 Plug Connector Remover AST tool# H 1849-6 Used for spark plug boot removal. Applicable to VW VR6 engine and is comparable to VW tool # T10029. - For the R and R of Spark Plug Connectors - Applicable to VW Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2227 - Install chain tensioner for camshaft roller chain and tighten to 40 Nm. Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip. - Rotate crankshaft two turns in direction of rotation of engine and check valve timing. NOTE: Replace crankshaft main seal on lower timing cover, if necessary Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5701 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 4217 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 6494 Special tools, testers and auxiliary items required ^ Torque wrench V.A.G. 1331 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A. G141 0 Note: ^ If a vehicle that has an axle shaft removed is to be moved, an outer CV joint must be installed in place of the axle shaft and be tightened to 50 Nm (37 ft. lbs.) otherwise the wheel bearing will be damaged. ^ Welding and straightening operations are not permitted on load-bearing or wheel-controlling suspension components. ^ Always replace self-locking nuts. ^ Always replaced corroded nuts/bolts Ride Height Alignment: Specifications Ride Height Vehicle trim height, "Zero position" In general! If a value lies outside the tolerance, the vehicle's trim height must be checked first. If the measured values are outside the allowed tolerances, the cause may be an incorrect vehicle attitude. Right-hand drive vehicles or for example vehicles with automatic transmission can lean to one side slightly. This is due to the installation position of components and weight distribution - It is absolutely necessary to measure dimension "a" on left and right hand sides. The O line on the roof means the horizontal position (zero position) of the vehicle. - Correct differences if necessary. It is possible to correct trim height imbalance for front axle by adding weight to top of strut tower and/or adding weight in trunk for rear axle, example: sand bags can be used, approx. 10 kg (22 lbs.) Page 3343 Oxygen Sensor: Locations Bank 1, Sensor 2 Oxygen Sensor Oxygen Sensor Location G130 Service and Repair Oil Filter: Service and Repair For further information regarding this component please refer to Lubrication Systems; Service and Repair. Oxygen Sensor and O2 Sensor Control After TWC, Checking Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control After TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (After Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair terminals 3 and 4 in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head free of leaks - Coolant temperature at least 85 °C = display group 04, display field 3 Functional check - Press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle (connecting scan tool and selecting engine electronics control module. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -3-, and -0- to input display group number 30 (030) and press - Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 - Check status of oxygen sensor control after Three Way Catalytic Converter (TWC) (display field 2). Page 4289 NOTE: If, during the "Update - Programming", a fault message is displayed: - Confirm that VAS 5051 or VAS 5052 diagnostic tool power supply is adequate and that ALL appliances with high electromagnetic radiation (i.e. mobile phones) are switched OFF. - The "Update - Programming" (flashing) process must then be started from the beginning using the "Repeat" button (arrow). DO NOT use the "Cancel" button. IMPORTANT! On NO occasion should the "Cancel" button be selected. Once "Update - Programming" (flashing) is complete: ^ Similar screen appears. ^ ECM Part Number and old software level is still displayed at (arrows). Note: New software level is not displayed until process is complete and fault memories have been erased; - Select the "Print", then "Screen" button. ^ VAS 5051 will print to printer immediately. ^ VAS 5052 will hold the print until process is complete and then you may take the tester to the printer for printing the screen. - Attach print to vehicle Repair Order. Once "Update - Programming" (flashing) is complete, the control module must be re-initialized. - Select the --> button. Page 4835 Fig. 3 Removing conductor strip - Place 3373 onto stop under solenoid valve plug. - Pull plug off with 3373 in direction of arrow. - Remove bolt -1-. Fig. 4 Removing valve body/unhooking operating rod When removing the valve body the manual selector valve -1- remains in the valve body. Shift selector lever/shaft into position "1". - Pull manual selector valve out until it is just possible to unhook operating rod -2-. - Secure manual selector valve so that it cannot fall out. Fig. 5 Inserting sealing plug Pull sealing plug out of housing before removing and installing freewheel. Otherwise, sealing plug and O-ring will be damaged. Fit O-rings to sealing plug. - Insert sealing plug in hole in transmission housing -arrow-. Page 4659 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5339 Volkswagen Canada, Inc. Page 6081 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. Page 1766 Wu-Ze Worldwide List of Engine Oils Page 5627 ^ Control module connector is not disconnected before On Board Diagnostic (OBD) 12 Connection for brake line ^ Hydraulic unit to left front brake caliper 13 Connection for brake line ^ Hydraulic unit to right rear wheel cylinder/ brake caliper 14 Connection for brake line ^ Hydraulic unit to left rear wheel cylinder/ brake caliper 15 Connection for brake line ^ Hydraulic unit to right front brake caliper 16 Brake line ^ Brake master cylinder/pressure rod piston circuit to hydraulic unit 17 Brake line ^ Brake master cylinder/floating piston circuit to hydraulic unit 18 Hex nut, self locking, 20 Nm (15 ft. lbs.) 19 Hex nut, self locking, 20 Nm (15 ft. lbs.) 20 Seal ^ Always replace 21 Vacuum hose ^ Install in brake booster 22 Sealing plug 23 Hex nut, self locking, 20 Nm (15 ft. lbs.) 24 Seal ^ For brake booster 25 Boot ^ Ensure boot is properly seated or suction noises may be noticed 26 Bracket Brake lines from brake master cylinder to hydraulic unit, connecting Fig. 1 Vehicles with ABS A Secondary piston circuit B Primary piston circuit 1 Hydraulic unit to right front brake caliper 2 Hydraulic unit to left rear wheel cylinder/brake caliper 3 Hydraulic unit to right rear wheel cylinder/brake caliper 4 Hydraulic unit to left front brake caliper Fig. 2 Vehicles with ABS/EDL A Secondary piston circuit Page 3626 - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Oxygen Sensor (O2S) And Oxygen Sensor Control Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. - The oxygen sensor (before catalytic converter) has a static regulation and can be differentiated from the oxygen sensor behind catalytic converter via a 6-pin connector. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degrees C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor before catalytic converter must be OK. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor Before TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals - End diagnosis and switch ignition off. If specified values are not obtained: - Test oxygen sensor wires. Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Page 3912 11 - 3-Pin Harness Connector. - White. - For Knock Sensor (KS) 1 - G61 -. - Sensor and harness connector contacts are gold plated. 12 - Supply Connection. 13 - Return Flow Connection. 14 - Intake Manifold Lower Section. Disassembling and assembling, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine /Intake Manifold/ Service and Repair. See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Lower Section, Disassembling and Assembling 15 - Seal. Always replace. 16 - Bracket. For Secondary Air Injection (AIR) pump motor - V101 - and secondary air inlet valve. - Secondary air system. Right Rear ABS Wheel Speed Sensor Wheel Speed Sensor: Locations Right Rear ABS Wheel Speed Sensor G44 - Right Rear ABS Wheel Speed Sensor Page 782 Wheel Speed Sensor: Locations Left Front ABS Wheel Speed Sensor G47 - Left Front ABS Wheel Speed Sensor Page 1548 Locations Remote Control Module: Locations J453 - Control Module For Multi-Function Steering Wheel - in 13 position relay carrier, behind driver's side lower footwell cover positions 5 and 6 Page 1805 Fuse arrangements in fuse bracket/battery S162 - Fuse -1- (30) In Fuse Bracket/Battery A/T - Pan Gasket Appears to be Leaking Transmission Pressure Test Port: Customer Interest A/T - Pan Gasket Appears to be Leaking Group: 37 Number: 01-01 Date: Mar. 5, 2001 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Supersedes T.B. Group Number 37 Number 00-02 to reflect new part number Condition Transmission appears to be leaking around ATF pan gasket. In most cases the leak is NOT caused by the ATF pan gasket, but by the main line pressure plug (arrow). ATF fluid flows down from main line pressure plug to pan seal, giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace with Part No: N 904 142 01 (plug with seal) - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases, a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. Page 4643 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3699 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5715 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 42 If no apparent connection problems: - Replace amplifier. If concern is poor FM reception: - Disconnect all amplifiers, tune radio to high-powered station for your area. - Connect amplifiers one at a time. If reception is indicated: - Disconnect that amplifier and move on to next amplifier. If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues: - Replace that amplifier and check again. If there is no reception change when disconnecting and reconnecting all amplifiers: - Replace diversity/antenna selection box. Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast) - Check connections at antenna base. - Check for corrosion at mounting. If corrosion is found: - Clean mount and apply anti-seize gel to mounting. If concern is no AM and/or little or poor AM/FM reception, - Replace antenna base. Section 4- Antenna cables If antenna cables are required: - Antenna cables - single DIN (Premium V) radio. Page 2844 - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -0button to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -4- and -1- to input display group number 41(041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 4. Page 518 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 4684 - Pull out clip -2- for locking cable -3-. - Pull locking cable out of steering lock -1-. - Remove selector lever handle. - Remove central console. - Unscrew bolt -arrow A- from locking cable support bracket. - Remove locking cable from selector mechanism and locking lever-arrow B-. - Pull locking cable out of instrument. Installing Note: The locking cable must not be kinked. - Adjust the locking cable offer installing. Page 4078 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 1707 Sealing plug (arrow 3) and cap (arrow 4) remain closed. If the ATF present in the overflow pipe runs out of the plug hole but no further draining is observed: Top up ATF in transmission. ATF, Topping Up With engine running. - Pry off plug securing cap -arrow- with a screwdriver. Cap locking device will be damaged, therefore always replace cap. - Remove plug from filler pipe. - Fill with ATF using V.A.G 1924 until ATF runs out of plug hole -arrow-. Note: An insufficient ATF filing as well as filling to excess affects the function of the transmission. - Install new seal to plug -arrow 1- and tighten to 15 Nm. - Install plug on filler pipe and secure with a new cap -arrow 2-. - Lock cap. Note: Always replace the cap. The cap secures the sealing plug. Page 1213 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1761 Lo-NI A/T - Leaks Near Pan Seals and Gaskets: Customer Interest A/T - Leaks Near Pan Group: 37 Number: 00-02 Date: Dec. 22, 2000 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Condition Transmission appears to be leaking around ATF pan. In most cases the leak is NOT caused by the ATF pan gasket but by the main line pressure plug (arrow). ATF fluid flows down from the main line pressure plug to the pan seal giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace seal, Part No: N 013 811 5 - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. - Test drive vehicle and inspect transmission for signs of leakage. Page 5680 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 5418 An initial quantity of required replacement parts (other than brake fluid) calculated according to vehicles located in your area will be shipped to you prior to the owner notification mailings. The parts are as shown. Additional required parts after depletion of the initial shipment must be ordered by you from your facing parts depot and not to exceed 50% of the vehicles left for repair according to your area vehicle allocation list. Please note: Excess parts ordered by you will either be denied shipment or requested to be returned. Parts Return All removed control units must be properly tagged with dealer number, repair order number and VIN, and immediately returned in the box of the new unit to: Volkswagen c/o 1601 Clay St. Detroit, MI 48211 ATTENTION: (Recall - WJ) Time Requirements Reimbursement To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below. Claims will only be paid for vehicles that show the WJ code in the OTIS campaign inquiry system on the day of repair. A copy of the print out must be attached and remain with your copy of the repair code. WJ Data Entry Procedure The system automatically enters the part number and labor applicable to the above listed codes. Page 6120 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5559 Brake Caliper: Service and Repair FS III Front Brake Calipers Notes: ^ Install all parts supplied in the repair kit. ^ New brake calipers are filled with brake fluid and are pre-bled. ^ Apply a thin coat of lubricant, Part No. G 052 150A2 to brake cylinders, pistons and seals. 1 Dust cap 2 Bleeder valve ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to threads before installing Specifications Piston: Specifications Piston Diameter Base value 80.985 mm Max. deviation from nominal 0.04 mm Page 233 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 652 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Load Reduction Relay Power Distribution Relay: Locations Load Reduction Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 492 If the specified values are not attained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector terminals: Terminal 1 + socket 92 - Terminal -2- + socket 83 - Terminal -3- + socket 117 - Terminal -4- + socket 84 - Terminal -5- + socket 118 - Terminal -6- + socket 91 - Wiring resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive or Ground. Specified value: infinity ohms If no malfunction is found in the wiring: - Check Engine Control Module (ECM) voltage supply. Refer to "Engine Control Module (ECM) Voltage Supply, Checking", See: Engine Control Module/Testing and Inspection Diagrams Ribbed Belt: Diagrams 6-cylinder Engine With Power Steering Pump And A/C Compressor 1 - Tensioning pulley 2 - Pulley - Generator (GEN) 3 - Ribbed belt - pulley, generator, compressor for air conditioner, vane pump for power steering, crankshaft/vibration damper and coolant pump 4 - Pulley - A/C compressor 5 - Pulley - power steering pump 6 - Crankshaft/vibration damper/pulley 7 - Pulley - coolant pump Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1812 Fuse arrangements in fuse bracket/battery Page 1494 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 2769 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 2-pin harness connector using wiring diagram. Terminal -2- + socket 39 - Wire resistance: Max. 1.5 ohms - Additionally, check wires for short to one another. - Additionally, check wiring for short to battery positive (B+) or Ground (GND). Page 5370 Owner Letter Page 1066 Brake Light Switch: Service and Repair Brake light switch, removing and installing/adjusting Two different styles of brake light switch were used in production. For servicing purposes they will be referred to here as "old style" and "new style". It is important to identify which style of switch is installed prior to servicing as each requires specific removal and installation/replacement procedures. Notes: On Diesel models and gasoline models with cruise control, Brake Switch -F- and Brake Pedal Switch (cruise control DFI) -F47- are integrated. The following procedures apply to all models regardless of switch. Only "old style" switches can be removed and reinstalled/adjusted. "New style" switches must NOT be reused after removal. Always replace. CAUTION: Should a brake light switch require replacement, only a specific "new style" switch is available (supercedes all previous part number versions). This switch requires that critical procedures be followed prior to and during installation. Preparation - Remove driver's side lower instrument panel cover. - Disconnect electrical connector from brake light switch. - Identify style of switch installed: "Old style" switch is identified by large (approximately 10 mm) plunger tip button, and square plunger shaft. Removing and installing/adjusting below. "New style" switch is identified by small (approximately 4 mm) plunger tip without button, and round plunger shaft. "Old style" brake light switch, removing and installing/adjusting Note: The following applies only to an existing, functional "old style" switch that is removed and reinstalled/adjusted. Removing - Turn switch counter-clockwise 90° - Pull switch out from retainer mounting hole. Installing/adjusting - Before installing, pull out plunger completely. - Depress and hold brake pedal in down position. - Note orientation of retainer tabs on switch and carefully insert switch into retainer mounting hole - Secure switch by turning clockwise 90° Page 3284 - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Initiating and Checking Control Module Versions Data Bus On Board Diagnostic Interface, On Board Diagnostic (OBD), Initiating, Checking Control Module Versions Test requirements: - All fuses OK according to wiring diagram - Voltage supply OK (at least 11.5 V). - Scan Tool VAG 1551 or VAG 1552 connected. NOTE: - Connecting Scan Tool. Refer to "Scan Tool Testing/Scan Tool Connecting and Initial Checks" - The following description applies only to Scan Tool VAG 1551. - Switch on ignition. - Switch on printer with the PRINT button (indicator lamp in button lights up). - Press button -1- to select operating mode 1 "Rapid data transfer". Indicated on display: Rapid data transfer HELP Input address word XX - Press buttons -1- and -9- to input "Gateway" address word 19. Indicated on display: Rapid data transfer Q 19 - Diagnostic Interface for Data Bus - Press -Q- button to confirm input. Indicated on display: Rapid data transfer Q Tester sends address word 19 Indicated on display (example only): 6N0909901 Gateway K <-> CAN 0001 Coding 00007 WSC 00000 Top line: Part No. of control module System designation (Gateway K <-> CAN) 1) Software level Bottom line: Coding 2) Workshop number 1) The Data Bus On Board Diagnostic Interface -J533- in instrument cluster is referred to in the OBD program as "Gateway". 2) Dependant on the control modules connected to the CAN Bus network. - Press -> button. Page 295 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 2250 Timing Chain Tensioner: Specifications Chain tensioner for roller chain............................................................................................................. ................................................................... 10 Nm Chain tensioner for camshaft roller chain .............................................................................................................................................................. 40 Nm Page 4738 - Tighten bolt -2- (8 Nm). - Fit cover to selector lever housing with new sealing rings. - Install tunnel heat shields front and rear. - Join exhaust system and secure with clamping sleeve. - Check selector mechanism. Page 5419 SUBLETS At -A- Glance For vehicles that, according to your information, cannot be corrected, and one of the codes below best describe the reason, please enter into the system one of the codes indicated, as applicable: Campaign Verification For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding campaign inquiry and verification system; other systems are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as minimize inconvenience to your customers, you are urged to service each vehicle at the scheduled service appointment time, supply a loaner vehicle for the day. Make sure that each vehicle is returned to the customer washed and cleaned inside. In the event the customer waits during the service, do not let them wait longer than specified for the recall repair service in the owner notification letter. Please make every effort to reduce inconvenience to customers. Service Help Dealer Personnel Information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Thank you for your cooperation. Overview This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Page 4763 - Clamp-off ATF cooler hoses with 3094 and disconnect at ATF cooler. - Remove ATF cooler -1- from transmission -arrow A-. Installing ATF cooler Install in reverse order but note the following: Replace ATF cooler O-rings. - When installing ATF cooler-1-, insert tab -arrow B- in opening on housing. - Tighten hex head bolt -arrow A- to 40 Nm. Page 2921 - When transmission has been securely supported, remove bolts for transmission carrier (arrows). - Remove pendulum support (arrows). - Lower transmission approx. 60 mm (2.4 in.) -a-. - Disconnect black connector from sensor. - Remove bolt and take sensor -1- out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 5244 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 3695 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Locations Yaw Rate Sensor: Locations G200 - Sensor for transverse acceleration (vehicles with ESP) Page 5482 ^ Guide switch through mounting hole (only fits in one position). ^ Seat switch fully into opening (pressing plunger against pedal to adjust. ^ Seat switch by turning it 45° clockwise. This action also turns the plunger shoe into the correct orientation to make electrical contracts in switch operate as well as locks in plunger adjustment. ^ Connect brake light switch connector. ^ Operate brake pedal to verify proper function. ^ Reinstall lower cover panel. 4 Accelerator - pedal 5 Hex bolt 6 Brake pedal 7 Pad 8 self-locking nut ^ 20 Nm (15 ft. lbs.) ^ Always replace 9 Bushing 10 Pivot pin Page 3652 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4905 NOTE: To tighten 12-point nut use wrench VAG 1756: - -Tighten 12 point nut to 200 Nm (148 ft. lbs.) and loosen 1/2 turn. - -Tighten 12 point nut to 50 Nm (37 ft. lbs.) + turn an additional 60°. If wrench is not available, 12-point nut can be tightened as follows. Tighten 12-point nut to 200 Nm (148 ft. lbs.) + loosen 1/2 turn (180°). - Mark point on nut with line (arrow A). - Mark 2nd line (arrow B) on edge of wheel hub 60° from first point. - Tighten 12-point nut until points A and B align. Engine Controls - MIL ON/DTC P0420 Stored in Memory PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0420 Stored in Memory Condition Update Programming, MIL ON, DTC P0420 Stored in ECM MIL ON with DTC P0420 Catalyst System, Bank1 Efficiency Below Threshold stored in ECM. 01 07 06 Jan. 22, 2007 2013839 Supersedes T.B. Group 01 number 06-25 dated Dec. 22, 2006 due to warranty table claim type information change. Technical Background The monitoring strategy for the catalytic converter is too sensitive causing unnecessary catalytic converter replacements. The updated programming of the ECM software makes the monitoring strategy more accurate. NOTE: DO NOT replace catalytic converter due to P0420 if older software level is installed. Production Solution No production change required. Service PROCEDURE: Engine Control Module Update - Programming (Flashing) Tip: When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update programming procedure first. The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc. If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming" (flashing) procedure: Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to have been tuned, and that any damage caused by the tuning of the ECM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties. For any repair requested by the owner under warranty or outside warranty that requires update programming, which will automatically wipe out the "Tuning" program, your Dealership should advise the owner of the above and get Owner's written consent (see attached Control Module Tuning form) to the update programming procedure. Tool requirements VAS 5051 or VAS 5052 (with Base CD V.10.01 and the Brand CD V.10.70.00 or higher). "Update - Programming" (flashing) CD MY99022VVR6CAT. Tip: Additional copies of the "Update - Programming" CD (Literature Number MY99022VVR6CAT) may be ordered from the Volkswagen Technical Literature Ordering Center. Vehicle requirements Battery MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update process can lead to ECM failure) (use an approved battery charger INC940 to maintain battery voltage). VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure. VAS 5052: connected to vehicle with battery voltage requirements met. Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF. Page 6473 VW/Audi axle nut set. Contains:6500-14, 6500-17, 6500 X-30, and 6500 X-32. - 14mm allen for VW Passat 1996-2001, Audi A4; front and rear axle bolts (AWD) - 17mm allen for 1998-2005 VW Passat, 1999-2004 Audi A6, 2002-2005 Audi A4; front and rear axle bolts (AWD) - 30mm 12 point socket for mid 1999-2005 VW Golf, Jetta, Cabrio, and Beetle; front axle nut - 32mm 12 point socket with a 3/4" drive, VW Touareg; front and rear axle nuts Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: 6500-14 - 14mm Allen Socket Page 3132 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4491 - Always replace seal -arrow- on ATF inspection plug. ATF Level, Checking Test conditions: Transmission not in emergency running mode, ATF temperature not above approx. 30°C - Vehicle level - Selector lever in "P", parking brake applied - Secure reservoir of ATF filling system V.A.G 1924 to vehicle. Connecting vehicle diagnosis, testing and information system VAS 5051 All functions which could previously be performed with V.A.G 1551 can also be performed with the new tester VAS 5051 in the operating mode "Vehicle self-diagnosis": Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 Brake Light Switch: All Technical Service Bulletins Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 94 06 07 August 1, 2006 2012628 Condition EPC/Glow Plug Light On, DTC P0571 Stored in ECM Memory and/or Lack of Brake Light Functionality Customer may state EPC/Glow Plug Light On and/or brake lights inoperative or intermittent. DTC P0571 Brake Circuit -F- Implausible Circuit stored in ECM Memory Vehicles Affected Technical Background Condition may be caused by sensitive software or improperly installed brake light switch due to imprecise repair instructions. Production Solution No production change required. Service Diagnosis If EPC light -K132- or glow plug light -K29- is ON: ^ Go to Section A. If brake lights are not operating correctly: ^ Go to Section B. Section A - EPC or Glow Plug Light ON ^ With key ON/engine OFF, depress brake pedal to verify proper brake light operation. If brake lights are not operating correctly: ^ Go to Section B. If brake lights are operating correctly: ^ Using VAS 5051/5052, check Engine Control Module (ECM) for DTC P0571. If displayed DTC is not P0571: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. If displayed DTC is P0571: ^ Print GFF log and clear DTC. Page 1296 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 2853 If the specified value is obtained: - Change to display group 32 as follows: - Press -C- button. - Press buttons -0-, -3- and -2- to input display group number 32 (032) and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 32 -> 12 - Check oxygen sensor control learned value at idling (additive) in display field 1. - Check oxygen sensor control value at part load (multiplicative) in display field 2. Page 473 Part 1 Page 4365 - Moisten sealing lips with ATF before installing - Turn cap slightly when installing 11. Intermediate spring ring - With spring supporting shell and compression springs 12. Piston - Sealing lips are vulcanized to piston - Moisten sealing lips with ATF before installing - Turn piston slightly when installing 13. Clutch housing - Before inserting the inner plate carrier corrugated washer (item 8), insert inner and outer plates in the clutch see Fig. 3 Fig. 1 Removing and installing circlip - Press piston cap with intermediate spring ring down far enough for circlip (arrow) to be inserted in groove. Fig. 2 Installing thrust plate and plates onto inner plate carrier - Install thrust plate -a- with smooth side facing inner plate and stepped side towards inner plate carrier. - Install 3 inner plates -b- and 2 outer plates -c-. - Clip in supporting ring with step (arrow). Note: Locate tabs correctly. - Installing corrugated washer and further plates in clutch housing. Page 5440 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Required special tools and equipment ^ VAG 1331 Torque wrench or equivalent ^ VAG 1410 Torque wrench or equivalent ^ VAG 1869/2 Brake pedal depressor or equivalent Component location: The ABS control module is bolted together with the hydraulic unit and is located in the engine compartment, left side. CAUTION! Brake lines in file area of file hydraulic unit should not be bent! Removing ^ For vehicles with a coded radio, obtain code. ^ Disconnect battery. Page 6002 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5241 Test Sep 7 - 9 Page 3137 Data Link Connector: Connector Locations Data Link Connector (DLC) Location: The DLC (arrow) is located behind a cover under the left side of the instrument panel. Page 1058 Part 1 Page 2207 - Crank engine toTDC Cyl. 1 position. Page 6361 Display group 002 Page 5093 Test Step 1 Diagram Information and Instructions Rain Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 915 Low Pressure Sensor / Switch: Description and Operation A/C Pressure Switch -F129A/C pressure switch -F129-F129- has three functions: - Switches the A/C clutch -N25- off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged). - Switches the A/C clutch -N25- off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out) - Switches on the second speed coolant fan -V7- when refrigerant circuit pressure increases. NOTE: - The presence of -F129- is engine dependant. Where -F129- is not used, high pressure sensor -G65- is used instead. - Always confirm system use of either -F129- or -G65- and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. - A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Page 2473 1. Coolant recovery bottle 2. Upper coolant pipe 3. Throttle valve control unit J338- 4. Heat exchanger for heating 5. Check valve 6. After-run coolant pump -V51- 7. ATF radiator,only vehicles with automatic transmission 8. Upper coolant hose 9. Radiator 10. Lower coolant hose 11. Thermostat housing 12. Lower coolant pipe 13. Oil cooler 14. Auxiliary radiator 15. Coolant pump 16. Cylinder block 17. Cylinder head Page 3583 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5692 Page 2529 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 6310 5. Clamp ^ Replace ^ Tensioning 6. Tie rod ^ 75 Nm (55 ft. lbs.) ^ Replacement parts are supplied preset ^ Vehicle alignment 7. Clamp with rubber sleeve 8. Return line 9. Nut ^ 22 Nm (16 ft. lbs.) 10. Clamp with rubber sleeve Installation position ^ Arrow on clamp points forward ^ Replace if threads in welded nut are damaged 11. Heat shield 12. Selflocking nut ^ 45 Nm (33 ft. lbs.) 13. Selector mechanism bearing bracket ^ Center on support (arrow A) with heat shield -11 -. 14. Bolt ^ 24 Nm (18 ft. lbs.) 15. Gasket ^ Observe installation instructions 16. Hydraulic line 17. Banjo bolt ^ M16x 1.5, 45 Nm (33 ft. lbs.) 18. Banjo bolt ^ M 14 x 1.5, 40 Nm (30 ft. lbs.) 19. O-ring ^ Replace 20. Steering gear Page 4202 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 1505 ASR/ESP switch removal is described below: NOTE: Switches cannot be removed using a screwdriver due to the strong springs in their engagement mechanisms. Removing - First remove driver's side heated seat control module/regulator. - Reach behind the ESP switch using the tip of assembly tool T10034. - Release the button for ESP -1- using assembly tool T10034 and remove from vent. - Disengage and disconnect electrical harness connectors. - Remove emergency flasher switch -2- and switch for heated rear window -3- in the same manner if necessary. Installing - Connect and engage all electrical harness connectors. - Insert switches into vent and engage. Specifications Oil Pressure Sender: Specifications Switch - Tightening Specifications Switch - Tightening Specifications 0.3 Bar Switch (Brown) 20 Nm 1.4 Bar Switch (Black) 25 Nm Page 4049 - Using multimeter and adapter cables from VW1594, measure supply voltage between terminals 1 + 5 of disconnected harness connector. - Switch ignition on. Specified value: min. 11.5 V - Switch ignition off. If no voltage is present: - Check wire between 5-pin harness connector terminal -5- and relay plate for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms - Check wire between 5-pin harness connector terminal -1- and Ground (GND) for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If there is no malfunction in the supply voltage: - Check activation. Checking activation WARNING! During the following test do not touch the connecting parts of the ignition coils or test cables. Page 3359 - Connect multimeter for voltage measurement to terminals 3 + 4 of connector to Engine Control Module (ECM) and measure primary voltage. Specified value: 0.40 to 0.50 Volts - Switch ignition off. If specified value is not obtained: - Test oxygen sensor wires. If specified value is obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- Bank 1: Vehicles with engine code AFP, item 9, - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. - Check wires between test box and 4-pin connector (to control module) for open circuit according to wiring diagram. Page 3554 Engine Speed Sensor: Testing and Inspection With Generic Scan Tool Check Engine Speed (RPM) Sensor Function The Engine Speed (RPM) Sensor -G28- detects engine speed and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test sequence Vehicles with engine code AFP - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Vehicles with engine code BDF - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Continuation for all vehicles 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 3255 - Measure sensor resistance between terminals 2 + 3 at connector to sensor. Specified value: 480...1000 Ohm - Check sensor for shorts between terminals 1 + 2 and 1 + 3. Specified value: infinite Ohm If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28-: Vehicles with engine code AFP, item 25, - Vehicles with engine code BDF, item 16. - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 108 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no DTC is found on sensor: - Connect test box to control module wiring harness connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Terminal 2 + socket 90 Terminal 3 + socket 82 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Remove sensor and check sensor wheel for secure fit, damage, and run-out. NOTE: There is a larger-sized gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If nothing seems to be wrong with the sensor wheel: - Replace Motronic Engine Control Module (ECM) -J220-. Page 974 ^ Disconnect wiring harness connector -1- from brake light switch -2-. ^ Remove brake light switch by turning (counterclockwise) and pulling switch out of retainer. Obtain the new brake light switch. Note: DO NOT press new brake switch plunger prior to installation. Pre adjustment of plunger will result in inoperative brake lights or brake lights staying on all the time ^ Grasp brake light switch and brake light switch plunger (black arrow). ^ ^Carefully pull the plunger out to full length. ^ Apply a light coat of lubricant Part No. G052142A2 (obtained locally and considered shop supply) to the end of the plunger (black arrow). Note: Lubricant must be applied to prevent premature wear of brake light switch plunger. Brake light switch can only be installed once! Installing switch a second time may result in an inoperable switch. Leave brake pedal in resting position. DO NOT press or hold up brake pedal during brake light switch installation. ^ Carefully insert brake light switch -2- fully into mounting hole (switch will only fit in the access hole one way), pressing the plunger against the brake pedal to adjust position. Tip: A ratcheting sound indicates the brake light switch plunger is being set in position. Page 3078 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Fuse Holder, Removing and Installing Fuse Block: Service and Repair Fuse Holder, Removing and Installing Fuse Holder And Relay Carrier CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Fuse Holder, Removing And Installing - Carefully pry-off side cover from instrument panel (left). - Remove driver's side instrument panel trim. - Remove screws -B- (2 Nm) and then press locking device -C- when doing this pull fuse holder -Aout inward. Page 1963 - Tighten bearing covers 2 and 6 in an alternating and crosswise pattern and then finish tightening to 20 Nm. - Install bearing cover 4 and also tighten to 20 Nm. - Clean camshaft gear cover at sealing surfaces and at cylinder head. - Clean old sealant from 3 mm bores in cylinder head gasket. Note: With the cylinder head installed, the bores in the cylinder head gasket are only partially visible. - Install camshaft sprockets with camshaft roller chain, adjust timing. - Fill 3 mm bores in cylinder head gasket with sealant AMV 188 001 02. - Coat cover sealing surface with AMV 188 001 02. Note: Make sure that the oil duct sealing O-ring is seated in the cover. - Install cover, start all fastening screws and lightly tighten by hand. - Tighten M8 fastening screws to 25 Nm, then tighten M6 fastening screws to 10 Nm. - Install camshaft roller chain tensioner and tighten to 30 Nm. Note: After installing new valve lifters, do not start the engine until after about 30 minutes. Hydraulic balancing elements must become properly seated (otherwise, valves will make contact with the piston). Page 727 - Installation position: Lower A-pillar, cove red by trim in footwell - Remove left A-pillar lower trim to remove 20 - Central control module Bolted to bracket on steering column under instrument panel - To remove, remove lower steering column trim first 21 - Hood lock Contact switch for anti-theft alarm - Installation position: In lock carrier Page 3150 Data Link Connector: Service Precautions Diagnostic Testers, No Communication, Possible Damage Due to Improper Installation of Aftermarket Accessories As per TSB Group 01; Number 02-03; Dated June 10, 2002 A condition may exist, on all models equipped with OBD II, where there is no communication with diagnostic testers or scan tools. This may be caused by improper installation of aftermarket accessories (including radios). WARNING! Improper installation of aftermarket accessories (not factory approved) in m.y. 1996 and newer vehicles may: Affect various vehicle systems connected to the OBD system! - Cause severe damage to V.A.G. 1551/1552 and other scan tools without over-current protection! DO NOT attempt to connect any scan tool which is not equipped with over-current protection to any vehicle in which an aftermarket accessory has been installed before checking communications through the Data Link Connector (DLC) by using the VAS 5051 or VAS 5052 Diagnostic Tools (which are protected against excessive current). Prior to connecting any scan tool (not equipped with over-current protection): - Check for installation of any aftermarket accessory (which may be improperly connected to vehicle OBD wiring). If aftermarket accessory is installed: - Attempt OBD communication using a VAS 5051 or VAS 5052 Diagnostic Tester. If OBD communication is possible: - The installation of the aftermarket accessory will not interfere with OBD communication through the DLC. If OBD communication is NOT possible: - Scan tools without over-current protection, (except the VAS 5051 or VAS 5052 Diagnostic Testers) cannot safely be connected to the vehicle DLC until the cause for problem is determined and eliminated: - Remove (disconnect) the aftermarket accessory and attempt communication again. If OBD communication is possible: - Continue diagnosis (using preferred diagnostic tester) with accessory disconnected. - Accessory installation should be corrected to ensure no future communication problems will occur. If OBD communication is NOT possible: - Additional diagnosis is required to determine the cause of the communication failure. Page 477 Page 3756 - Disconnect 2-pin connector from motor -arrow-. - Connect VAG 1527B diode test lamp to disconnected attachment plug using auxiliary cables from VAG 1594. The LED should illuminate. If the LED illuminates (power supply OK): Turn off ignition. - Replace air pump motor (V101). If the LED does not illuminate: Clip on 2-terminal attachment plug. - Start control element diagnosis and trigger air pump relay -J299-. - Check DTC memory. - Read-out readiness code. - If fault memory was erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. Page 5420 Special Tools: Section A Section A - Check ABS Control Module Part Number ^ Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column ^ Switch ignition to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics." ^ Read control module part number and code located in the upper right corner of the screen ^ If ABS control unit part number is 1C0 907 379 C, press <-- button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B ^ If ABS control unit part number is not 1C0 907 379 C no further work is required, press <-- button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code ^ Drive vehicle into hoist area ^ Raise vehicle on hoist Page 1027 ^ This switch can be identified by the larger (approx. 10 mm) plunger tip and square shaft (arrow). - Remove brake switch by turning left 90° Install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511D: Installing below). Brake switch, Part No: 1J0 945 511B, C or D, removing: ^ These switches can be identified by the smaller (approx. 4 mm) plunger and round shaft (black arrow). - Remove brake switch by turning left 45° When replacing after removal, install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511 D: Installing below). 2. Brake switch, Part No: 1J0 945 511 D: Installing: CAUTION! This version switch contains an internal switch which can be damaged if not installed and adjusted properly. DO NOT depress plunger prior to installation. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Page 2065 Ribbed Belt: Testing and Inspection Ribbed Belt, Checking NOTE: Always replace ribbed belt if found to be faulty. This will avoid related break-downs or operating problems. - Lift vehicle and check condition of ribbed belt -1-. - Crank engine by hand at vibration dampener/pulley -arrow-. Check ribbed ribbed belt for: - Sub-surface cracks (cracks, core ruptures, cross sectional breaks) - Layer separation (top layer, cord strands) - Base break-up - Fraying of cord strands - Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks- surface cracks) - Traces of oil and grease Page 2863 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 6- pin harness connector for open circuit according to wiring diagram. Terminal -4- + socket 5: Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 6-pin harness connector terminal -3- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms Aging Check Oxygen Sensor 1 Aging, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1788/10 engine speed adjuster Test conditions - Coolant temperature at least 85 °C display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 1271 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor After TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control After TWC, Checking, With Manufacturer's Scan Tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control After TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 1757 AC-Bu Page 5979 Part 1 Diagram Information and Instructions Shift Interlock Solenoid: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 3062 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Check wiring between test box and 5-pin harness connector -1- for open circuit according to wiring diagram. Terminal -1- + socket 26 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Check wiring additionally for short circuit to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: Page 83 If no apparent connection problems: - Replace amplifier. If concern is poor FM reception: - Disconnect all amplifiers, tune radio to high-powered station for your area. - Connect amplifiers one at a time. If reception is indicated: - Disconnect that amplifier and move on to next amplifier. If at any point in reconnecting amplifiers there is a loss in reception and there are no connection issues: - Replace that amplifier and check again. If there is no reception change when disconnecting and reconnecting all amplifiers: - Replace diversity/antenna selection box. Jetta / Golf / Passat (non W8) - Antenna system (Amplified Antenna Mast) - Check connections at antenna base. - Check for corrosion at mounting. If corrosion is found: - Clean mount and apply anti-seize gel to mounting. If concern is no AM and/or little or poor AM/FM reception, - Replace antenna base. Section 4- Antenna cables If antenna cables are required: - Antenna cables - single DIN (Premium V) radio. Locations Air Injection Pump Relay: Locations Component Location Component View Page 3677 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Connect multimeter to measure voltage between test box sockets -2- + -54-. - Switch ignition on. - Lift vehicle at left-front. - Rotate front wheel and observe voltage display. Specified value: between 0 and at least 4 Volts, fluctuating. NOTE: If necessary, hold the right-front wheel to prevent it from turning. If the display does not fluctuate: - Check wiring to speedometer/speedometer sensor. - Check DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 314 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 5556 ^ Do not damage when inserting piston Front caliper piston, removing and installing Special tools and equipment required ^ 3409 Wedge ^ VAG 1331 Torque wrench or equivalent ^ Piston resetting tool Removing ^ Force piston out of brake caliper housing using compressed air. Note: Place a piece of wood in the recess to prevent damaging the piston. Page 4133 Shift Interlock Solenoid: Service and Repair 5 Speed Automatic 09A Shift lock solenoid -N110-, removing and installing Removing Check whether a coded radio is fitted. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - Switch ignition off and disconnect battery Ground strap. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - -Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Unclip shift lock solenoid -N110- from retainer arrows A-. - Pull solenoid out of locking pawl -arrow B-. Page 359 Control Module HVAC: Diagrams Climatronic Control Module Control Modules - Connector Pin-out Page 4720 - Check selector lever cable and adjust if necessary. - Check ignition key withdrawal lock. Selector Mechanism Disassembling and Assembling Selector mechanism, disassembling and assembling Note: Lubricate mounting points and contact surfaces with grease, Part No. G 052 142 A2. 1. Selector lever handle - Removing and installing 2. Sleeve - Locates in selector lever handle - Prevents selector lever handle from being pulled off 3. Cover - With symbol Page l - Clipped into frame -item 5 4. Printed circuit - Can be checked in electrical test and in measured value block 5. Frame 6. Cable clip - Clipped into frame -item 5 7. Bracket - For selector lever cable Page 936 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3036 Display Group 050 - Observe display in display field 4. Display must show Compr. OFF. - Switch air conditioning system on. - Select lowest temperature and highest blower speed. The display in display field 3 must change to A/C-High. The display in display field 4 must change to Compr. ON. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 4698 Part 2 Page 6514 Wheel Bearing: Aftermarket Tools Rear Wheel Bearing Press AST tool# 3420 VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle. - VW/Audi Rear Wheel Bearing Press - Applicable to Newer Golf, Jetta and New Beetle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 21 In the trip odometer counter display "5000" appears. - Press and hold reset button for trip odometer counter for 2 seconds to move to the next display and enter the next digit. In the trip odometer counter display "5000" appears and the second digit blinks. - Press reset button for trip odometer counter until valid second digit of secret number is displayed, e.g. "3". - Press and hold reset button for trip odometer counter for 2 seconds to move to the next display and enter the next digit. In the trip odometer counter display "5300" appears and the third digit blinks. - Press reset button for trip odometer counter until valid third digit of secret number is displayed, e.g. "4". - Press and hold reset button for trip odometer counter for 2 seconds to move to the next display and enter the next digit. In the trip odometer counter display "5340" appears and the fourth digit blinks. - Press reset button for trip odometer counter until valid fourth digit of secret number is displayed, e.g. "9". In the trip odometer counter display "5349" appears (example). - When all four digits are entered, press and hold reset button for trip odometer counter for 4 seconds to complete process. If the valid secret number has been input correctly: - trip odometer display is shown again in trip odometer counter - warning light for anti-theft immobilizer stays on NOTE: - The immobilizer system is now deactivated. - Three attempts to input the secret number correctly are possible immediately. The next three attempts will not be possible for at least 10 minutes if the ignition remains switched on continuously during this time. - After the secret number has been input incorrectly three times, and the ignition switched off, the control module is locked. "FAIL" appears in the trip odometer display counter in the instrument cluster. - The waiting time between each set of attempts doubles each time to a maximum time of 255 minutes. - If during the input procedure no key/button operation occurs for longer than 30 seconds, the emergency start attempt is interrupted. - Switch ignition off and then start engine. The emergency start function is not operable again and must be reactivated if: - 5 minutes have elapsed since the ignition was switched off and the ignition key removed from the ignition lock. - 45 minutes have elapsed since the ignition was switched off, but an ignition key remained inserted in the ignition lock. - Upon beginning an adaptation function with VAG 1551. Page 3707 Page 2760 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 5128 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 3627 Wiring Test - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. - Check wires between test box and 6-pin connector (to control module) for open circuit according to wiring diagram. Terminal 1 + socket 70 Terminal 2 + socket 71 Terminal 5 + socket 51 Terminal 6 + socket 52 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7, - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2272 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long and measure battery voltage. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cu.cm/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.2 volts is measured at battery. Since the voltage at the pump is approx. 2 volts less than battery voltage, there is a minimum delivery rate of 200 cu.cm/30 s. If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply line -1- from fuel filter input. NOTE: Depress buttons on hose connections to do so. - Connect pressure gauge (VAG1318) with adapter (1318/17) to hose. - Repeat test of delivery quantity. If minimum delivery rate is obtained now: - Replace fuel filter. If minimum delivery rate is still not obtained: - Remove Fuel Pump (FP) unit and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 396 Part 2 With Manufacturer's Scan Tool Intake Air Temperature Sensor: Testing and Inspection With Manufacturer's Scan Tool Intake Air Temperature Sensor -G42- Checking NOTE: The Intake Air Temperature (IAT) sensor -G42- is a part of the Mass Air Flow (MAF) sensor -G70- and cannot be replaced separately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram - VAG1921 hose clip pliers - Chilling spray (commercially available) Test sequence NOTE: Only gold plated contacts must be used to repair The contacts in the intake air temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read intake air temperature value in display field 4. Page 5141 Part 1 Page 1899 Pulling bearing inner race out of hub Removing circlip Pressing wheel bearing out of wheel bearing housing Greasing hole with Molikote grease completely Molykote grease, G 052 723 A2 Page 4718 41. Gasket - Always replace 42. Selector lever cable - Do not bend or kink - If the outer cable is damaged the selector lever cable must be renewed - Lightly grease ball socket and cable ends before installing 43. Lever - For selector shaft 44. Support bracket - For mounting selector lever cable or transmission 45. Circlip - Always replace J386 - Door Control Module, Driver Side Power Window Control Module: Locations J386 - Door Control Module, Driver Side J386 - Door Control Module, Driver Side - in driver's door, on component carrier - integral with window motor -V147 Page 5031 - Remove cable support bracket from transmission (arrows). If necessary, unclip hose at cable support bracket first. - Carefully pry cover off center console (arrows). - Pull cover rearward off center console. - Destroy clip (arrow) and pull gear shift knob off with cover. - Remove rubber cover, if fitted. Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 4820 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5959 Starter Motor: Service and Repair With 5-Speed Automatic Transmission 09A Removing Starter, Removing And Installing Special tools, testers, measuring instruments and auxiliary items required - VAG 1331 Torque wrench (or equivalent 5 - 50 N.m) - VAG 1332 Torque wrench (or equivalent 40 - 200 Nm) Starter (vehicles With 5-speed Automatic Transmission 09A), Removing - Remove engine cover. - Switch off ignition. - Disconnect battery Ground (GND) strap from battery negative post Locking Pin - AST Tool # 3242 Crankshaft: Tools and Equipment Locking Pin - AST Tool # 3242 Locking Pin AST tool# 3242 Used to lock the crankshaft in T.D.C. position on VW/Audi 2.7L and 2.8L V-6 engines. Also applicable to: Audi with 4.2L V8(4v) (BVJ) and 4.2L V8(5v)(BHF) engines. - Used to Lock the Crankshaft in the TDC Position - Applicable to: VW/Audi 2.7L and 2.8L V-6 Engines Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: 3243 - Camshaft Alignment Tool Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 4664 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Technician Safety Information Fuel Injector: Technician Safety Information Safety Precautions WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be noted: - Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed. - The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or tester cables. Observe the following Warning if test and measuring instruments are required during a road test: WARNING! Test and measuring instruments must be secured to the rear seat and operated by a 2nd person from this location. If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered. If the engine is to be turned at starter speed without starting: - Disconnect 5-pin harness connector from ignition coil (arrow). - Pull fuse No. 32 out of fuse holder. NOTE: Removing fuse 32 interrupts the voltage supply to the fuel injectors. Safety Precautions (Read Measuring Value Block) Observe the following if test and measuring instruments are required during a test drive: Recall 04V584000: Hazard Switch/Relay Replacement Hazard Warning Switch: All Technical Service Bulletins Recall 04V584000: Hazard Switch/Relay Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 2000-2002 Volkswagen/GTI 2000-2002 Volkswagen/Jetta 2000-2002 Manufacturer: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 04V584000 RECALL DATE: Dec 13, 2004 COMPONENT: Exterior Lighting: Hazard Flashing Warning Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 350000 SUMMARY: On certain passenger vehicles, the hazard switch and flasher system function may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays which occurs due to substantially increased electrical current load from higher wattage turn signal bulbs. CONSEQUENCE: This may result in intermittent or inoperative turn signal and hazard flasher function. REMEDY: Dealers will replace the hazard flasher switch/relay kit. The recall is expected to begin during february 2005. Owners should contact Volkswagen at 1-800-822-8987. NOTES: VW recall No. VX. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 5492 ^ Do not damage when inserting piston Front caliper piston, removing and installing Special tools and equipment required ^ 3409 Wedge ^ VAG 1331 Torque wrench or equivalent ^ Piston resetting tool Removing ^ Force piston out of brake caliper housing using compressed air. Note: Place a piece of wood in the recess to prevent damaging the piston. Page 1148 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 4563 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Page 1237 Oxygen Sensor: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Page 5094 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Page 3304 - Displayed after pressing C button. Indicated on display: Read Measuring Value Block HELP Enter display group number XXX - Enter alternate display group number as needed See tables beginning, See: Scan Tool Testing and Procedures/Measuring Value Blocks (Function 08)/Interpreting Display Groups NOTE: - Display fields always show actual values transmitted from senders and sensors. However, instrument cluster display values can differ from those in the display fields due to internal filtering. - Other display groups are possible, but are not required for On Board Diagnostic program! - Display fields in display groups 125 and 126 provides the CAN-Bus function status codes of various control modules connected to the "Powertrain" CAN-Bus network. - If a vehicle is not equipped with control module(s) listed in the following display groups, the applicable display field remains blank. Check correct coding of CAN-Bus On Board Diagnostic (OBD) interface -J533-. See: Programming and Relearning - Display field content differs between VDO and MMO instrument clusters! Interpreting Display Groups Display Groups, Interpreting With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 3375 Display Group 034 If the specified values are obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specified values are not obtained: - Carry out road test to free oxygen sensor of possible residues and repeat test. Observe the safety precautions when carrying out a road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module: Locations 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module location The control module is located in plenum chamber. Page 5144 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2902 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 3872 Fuel: Technical Service Bulletins Fuel System - Neutralizing Fuel For Fuel Tank Disposal 20 08 06 Oct. 13, 2008 2011499 Supersedes T.B. Group 20 number 06 01 dated February 17, 2006 due to additional model and model year applicability. Vehicle Information Condition Fuel Tanks Removed from Vehicles, Neutralizing Fuel Technical Background Flush procedure using emulsifier to neutralize fuel tanks before shipping. Production Solution No production change required. Service This Technical Bulletin applies to fuel tank replacement, whether covered under warranty or carried out at the customer's expense. Once a fuel tank has been replaced in a vehicle, the old tank must be flushed to properly neutralize any remaining gasoline or diesel fuel. This procedure pertains to any fuel tank, whether being returned to the Warranty Test Center or being disposed of by other means. WARNING: The fuel tank must be neutralized before shipment or disposal. To obtain the emulsifier, order Qty. 1 of Part No. D 200 201L (1 Liter). This Liter can be used to neutralize two (2) fuel tanks. Flushing / Neutralizing Fuel tank removed. ^ Pour 0.5 Liter of emulsifier into tank. ^ Add 4 Liters water, then cap off all openings. ^ Agitate tank for at least 30 seconds, turning tank assembly in all directions to allow emulsifier to reach all areas inside the tank. ^ After agitation, drain neutralized mixture into special container labeled "Waste Material-Hazardous" and dispose of properly in accordance with local, state and Federal EPA regulations. For warranty repairs, add 0.5 Liter of the emulsifier to the warranty claim, using Qty. 0.5 of Part No. D 200 201L. NOTE: If a fuel tank is requested to be shipped to the Warranty Test Center: Ship only after tank has been neutralized with the emulsifier. DO NOT ship fuel tank by air. Warranty N/A Page 1735 Warranty Required Parts and Tools Fuel System - Fuel Tank Ground Strap Installation Ground Strap: Technical Service Bulletins Fuel System - Fuel Tank Ground Strap Installation 20 07 02 Feb. 27, 2007 2001950 Supersedes Technical Bulletin Group 20 number 00-02 dated March 15, 2000 due to inclusion into ElsaWeb and Metadata. Affected Vehicles Condition Replacement Fuel Tanks, Installing Grounding Strap Technical Background All replacement fuel tanks do not come with grounding strap (wire) installed. Production Solution No production change required. Service Tip: The grounding strap must be installed into all replacement fuel tanks. Install grounding strap, see Required Parts and Tools, into replacement fuel tank as follows: - Remove fuel filler cap - note cautions written on cap. - Bend up tab on inside of fuel filler pipe as shown -arrow-. Tip: Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 5049 - Insert spring so that spring extension -A- lies above pin (arrow). - Pull spring extension -B- down so that it reaches below pin (arrow). Page 3356 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 4-pin harness connector -1- to Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130-. Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -1- and -2(harness connector to Engine Control Module (ECM)). - Start engine and run at idle - Measure voltage supply and observe display group 41, display field 4. Display: Htg.aC.ON - Specified value: 11.0-14.5 V Display: Htg.aC.ON/Htg.aC.OFF (alternating) - Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 4711 22. Gasket 23. Cover 24. Bolt 25. O-ring 26. Bolt, 8 Nm 27. Contact spring 28. Bolt, 4 Nm 29. Clip 30. Steering lock 31. Bolt 32. Shift lock solenoid -N110- 33. Cable tie 34. Spring 35. Locking pin 36. Nut, 13 Nm 37. Washer 38. Nut, 25 Nm 39. Locking cable 40. Circlip 41. Gasket 42. Selector lever cable 43. Lever 44. Support bracket 45. Circlip Page 1859 * 1 Indicator unit in the center of the panel ** 2 Indicator unit in the speedometer - Release button -1-. - Turn adjustment button -1- beside the tachometer. The service now indicated on the odometer will be reset to zero, and the indication on the odometer display or the central display returns to its normal state. - Turn the ignition off. Resetting service interval indicator, from 2008, on Instrument Panel Note: The service interval indicator must be reset at every inspection service! Reset the indicator as explained: - Turn the ignition off. Page 5401 <-- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Note: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole <-- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket ^ Remove hydraulic unit with control module from bracket and place on a clean level work bench ^ Remove the new ABS control module (1C0 907 379 J) from package <-- Insert new adaptor -3- from kit into new ABS control module <-- Push adaptor down until clips -4- snap into position CAUTION! THE ADAPTER CAN ONLY BE PRESSED BE REMOVED AGAIN WITHOUT PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 2639 Electronic Throttle Control Module: Testing and Inspection Throttle Valve Control Module J338, Checking With Generic Scan Tool Throttle Valve Control Module, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of throttle valve control module. Function The throttle valve activation occurs via an electric motor (throttle drive) in the throttle valve control module. It is activated by the Engine Control Module (ECM) according to specifications of the two sensors, Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-, function of the E-gas system. Components of Throttle Valve Control Module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for throttle drive (power accelerator actuation) -G188Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Throttle valve must not be damaged or dirty. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 17: Throttle valve position (absolute)." - Check specified value of throttle valve position (absolute) at idle stop: Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 4335 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1211 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 26 Terminal 3 + socket 27 Wire resistance: max: 1.5 Ohm Page 3538 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 5340 Page 329 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2968 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Page 2263 - Measure resistance between terminals of the respective valve for camshaft adjustment. Specified value: 10...18 Ohms If specified value is not obtained: - Replace control housing for camshaft adjustment, item3. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit according to wiring diagram Wire resistance: max: 1.5 Ohms If resistances and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 3628 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor After TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control After TWC, Checking, With Manufacturer's Scan Tool. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control After TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 4446 Final Drive Fluid: Fluid Type Specifications 4 Speed 01M Planetary gearbox fluid Capacity ............................................................................................................................................... ............................ 5.3L (filled for life, no change) Type ....................................................................... .............................................................................................................................................. VW ATF VW Part no. ......................................................................................................................................... ........................................ G 052 162 A1 (0.5 liter) VW Part no. .......................................................... ....................................................................................................................... G 052 162 A2 (1.0 liter) Final drive Initial filling ........................................................................................................................................... .................................................................... 0.75L Oil change ............................................................ .................................................................................................................... Filled for life (no change) Type ..................................................................................................................................................... .................. Gear oil SAE 75W-90 (synthetic oil) VW Part no. ............................................................. .................................................................................................................... G 052 145 A1 (0.5 liter) VW Part no. ......................................................................................................................................... ........................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... ................................................... 7.0L (filled for life) Type ..................................................................................................................................................... ........................................................................... ATF VW Part no. ......................................................................................................................................... ............................................................ G 052 990 A2 Engine - Measurement Of Oil Consumption Engine Oil: Technical Service Bulletins Engine - Measurement Of Oil Consumption 17 11 01 March 25, 2010 2017813 Supersedes T.B. V171003 dated July 12, 2010 to include additional model year applicability and special tool purchase information. Vehicle Information Condition Oil Consumption Measurement Customer states oil consumption is higher than the Volkswagen oil consumption standard of up to 0.5 quarts per 600 miles, or 0.5 liters per 1000 km. Technical Background In order to provide effective lubrication and cooling of internal engine components, all internal combustion engines consume a certain amount of engine oil. Oil consumption varies from engine to engine and may change significantly over the life of the engine. Typically, engines with specified break-in periods consume more oil during the break-in period, and the oil consumption will stabilize after the break-in period. Refer to the Owners Manual for specific break-in procedures. Under normal conditions, the rate of oil consumption depends on the quality and viscosity of the oil, the RPM at which the engine is operated, the ambient temperature and road conditions. Further factors are the amount of oil dilution from water condensation or fuel residue and the oxidation level of the oil. Production Solution Not applicable. Service If the customer complains that their engine is apparently consuming oil in excess of the Volkswagen oil consumption standard above, an oil consumption test must be performed using the test plan in the VAS 5051 B, 5052/A, 6150 tester, before any repair is carried out. Tip Using the VAS tester, navigate to the Oil consumption measurement using one of the provided methods below: ^ GFF- Function/Component Selection: Powertrain >> Engine >> Systems capable of self diagnosis >> Motronic engine control >> Functions >> General functions» Oil consumption measurements. ^ GFF- Function/Component Selection: Drivetrain >> Engine >> Lubrication >> Sub-systems, marginal conditions >> Oil consumption measurements. 1. Follow VAS 5051B, 5052/A, 6150 test protocol exactly, and document all information on oil measurement sheets. 2. Archive the VAS 5051B, 5052/A, 6150 diagnostic log and oil measurement test sheet (attached) in the dealership vehicle service file. 3. When the customer returns the vehicle to the dealership after a minimum of 630 miles (1014 km), complete part # 2 of the oil consumption test plan Page 5326 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 3568 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 26 Terminal 3 + socket 27 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm Page 2780 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 1806 S162 - Fuse -1- (30) in fuse bracket/battery S163 - Fuse -2- (30) In Fuse Bracket/Battery S163 - Fuse -2- (30) in fuse bracket/battery S164 - Fuse -3- (30) In Fuse Bracket/Battery Page 6270 - Turn tightening device in direction of arrow to relieve tension on ribbed belt. - Mark direction of ribbed belt rotation. - Remove ribbed belt. - Remove belt pulley hex bolt. - Clamp off suction hose with hose clamps -3094-. - Open spring clip -3- and pull off suction hose with special tool VAS 5024. - Remove banjo bolt -4-. - Seal pressure line/hose with a plastic bag or similar. - Remove hex bolts -1- and -2-. - Remove pump. Installing - Fill power steering pump with hydraulic oil, via suction union. - Turn hub by hand until oil comes from pressure side. - Install p/s pump on bracket and tighten bolts to 25 Nm (18 ft. lbs.). Page 4267 After selecting "Update - Programming" function, new program version as listed below will install: ^ 0009 for ECM Part No.: 021 906 018 A (1999) ^ 0009 for ECM Part No.: 021 906 018 B (1999) ^ 0007 for ECM Part No.: 021 906 018 K (2000) ^ 0007 for ECM Part No.: 021 906 018 M (2000) ^ 0003 for ECM Part No.: 021 906 018 Q (2000) ^ 0005 for ECM Part No.: 021 906 018 R (2001) ^ 0005 for ECM Part No.: 021 906 018 S (2001) ^ 0004 for ECM Part No.: 021 906 018 AA (2002) ^ 0004 for ECM Part No.: 021 906 018 T (2002) - By selecting the --> button, the programming procedure begins. Similar screen appears: The previous data in the ECM is erased and the new data is being transferred to the module from the flash CD. Note: Approx. flashing time is 24 minutes. Page 4068 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 1062 Page 3467 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3085 Page 5495 Brake Caliper: Service and Repair FS III Front Brake Calipers Notes: ^ Install all parts supplied in the repair kit. ^ New brake calipers are filled with brake fluid and are pre-bled. ^ Apply a thin coat of lubricant, Part No. G 052 150A2 to brake cylinders, pistons and seals. 1 Dust cap 2 Bleeder valve ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to threads before installing Page 1822 Part 2 Page 3149 Page 5282 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 4350 - Tighten both bolts -arrows B- to 25 Nm. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Reconnect Ground strap to battery. - Check selector mechanism. - Enter radio code. Oxygen Sensor and O2 Sensor Control After TWC, Checking Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control After TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (After Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair terminals 3 and 4 in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head free of leaks - Coolant temperature at least 85 °C = display group 04, display field 3 Functional check - Press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle (connecting scan tool and selecting engine electronics control module. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -3-, and -0- to input display group number 30 (030) and press - Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 - Check status of oxygen sensor control after Three Way Catalytic Converter (TWC) (display field 2). Page 1315 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (5 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission) Page 3116 - Connect multimeter between terminal 2 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 4-pin connector terminal 2 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with 2-pin clutch vacuum vent valve switch - Check wire between test box and 2-pin connector for open circuit according to wiring diagram. Terminal 2 + socket 39 Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch - Check wire between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 39 Wire resistance: max: 1.5 Ohm Page 3319 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 1183 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 5092 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 3395 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3060 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Bridge harness connector terminals -1- + - 3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor - G70-, item -4-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display reads approx. 140 °C: Page 5043 I Removing and installing selector lever and boot II - Servicing gear lever and gear lever housing III - Assembly overview: Removing and installing operating cables Removing and installing selector mechanism. Adjusting selector mechanism. Note: Before working on the selector mechanism, disconnect ground strap from battery in engine compartment. - Note radio code on vehicles with coded radio. Special tools and equipment required Page 3357 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin connector according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 4-pin harness connector terminal -1- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms With Generic Scan Tool Oxygen Sensor And Oxygen Sensor Control Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 3607 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin connector according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 4-pin harness connector terminal -1- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms With Generic Scan Tool Oxygen Sensor And Oxygen Sensor Control Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 4544 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 2644 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Measure resistance from throttle valve drive between terminals -3- and -5- Specified value: 1.0-5.0 ohms If the specified value is not obtained: - Replace throttle valve control module - J338- , item 10. Refer to "Intake Manifold Upper Section, Disassembling and Assembling" under "Fuel Delivery and Air Induction/Variable Induction System", - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt Engine Control Module (ECM) to throttle valve control module. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check accelerator pedal sensor. If the voltage supply and wiring is OK: - Replace Engine Control Module (ECM). Checking voltage supply and wiring to control module Page 2342 Note: Cooling system flushing due to coolant mixing or incorrect coolant is not covered by warranty. Warranty Information Only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) switch Page 2105 Va-To Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2545 Thermostat: Service and Repair Thermostat Removing and Installing Note: Refer below, to both "Cooling System, Engine Side" and "Thermostat Housing, Disassembling and Assembling" information for thermostat service. Cooling System, Engine Side 1. Pressure cap - Check with V.A.G 1274 test instrument and V.A.G 1274/9 adapter - Test pressure 1.4 - 1.6 bar (20 to 23 psi) 2. O-Ring - Replace if damaged 3. Coolant recovery bottle - Check for leaks in cooling system using V.A.G 1274 test instrument and V.A.G1274/8 adapter 4. Bolt. Torque Specification: 10 Nm (7 ft. lbs.) 5. Upper coolant pipe - Clipped into the bulkhead 6. To heat exchanger 7. Throttle valve control unit (J338) - Heated by coolant 8. To upper coolant hose 9. To upper radiator 10. Gasket - Replace 11. To lower radiator 12. Thermostat housing 13. Coolant feed pump (V51) Check 14. From heat exchanger 15. Bolt. Torque Specification: 25 Nm (18 ft. lbs.) 16. Oil cooler - Coat contact surfaces outside of sealing ring with AMV 188 001 02 - Ensure free movement among surrounding components 17. Screw plug 18. Coolant pipe 19. Coolant pump - Observe installation position - Check for smooth running - Replace completely if damaged or if leaking 20. Bolt. Torque Specification: 15 Nm (11 ft. lbs.) 21. Pulley for coolant pump 22. 25 Nm (18 ft. lbs.) Page 148 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 4338 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 4276 When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update programming procedure first. NOTE: Non-observance of the following points may lead to ECM failure! VAS 5051 or VAS 5052 must always be connected to the approved power supply at the approved voltages. Under no circumstances should the power supply be interrupted or the diagnostic connector unplugged during the update programming procedure. Any appliances with high electromagnetic radiation (i.e. mobile phones) must be switched OFF. Tip: Before update programming, delete the fault memory in the ECM. Update programming is not possible when an EEPROM fault is active. Reprogram ECM with CD - Part number MY99022VVR6CAT. - Insert the programming CD into the VAS 5051 / 5052, and access the ECM. Tip: If the update programming button does not appear, the latest version has already been installed to the level below. - Programming starts by pressing the "Update Programming" button and following the on screen prompts. NOTE: Once update programming begins, on NO occasion should the Cancel button be selected. - Press the "Update Programming" button. Tip: Once update programming is complete, it is recommended to use 1001- Compiling Services prompt to clear faults stored in various control modules. - Reset readiness code. Warranty Required Parts and Tools No Special Tools required. Page 2640 - Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly. - Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop: - End diagnosis and switch ignition off. If specified values are not obtained: - Disconnect the 6-pin connector at the throttle valve control module (arrow). Check resistance - Measure resistance of Throttle drive (power accelerator actuation) -G186- in Throttle Valve Control Module -J338- between terminals 3 + 5 Specified value: 1.0...5.0 Ohm If specified value is not obtained: - Replace Throttle Valve Control Module -J338-: With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 4318 Part 2 Page 2709 If the specified value is not obtained: - Remove wiper arms and plenum chamber cover. Relay Locations Compiled From Every Wiring Section 1998-2004 Wiper Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5610 Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing Note: Tire and wheel removal is not necessary Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening Note: The label showing supplier code is upside down in vehicle ^ If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C ^ If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation ^ Obtain radio code and record radio preset stations ^ Turn Ignition Switch to "OFF" position ^ Open hood and place fender cover in position ^ Disconnect the ground cable (GDN) from the negative (-) battery terminal <-- Disconnect electrical connector -1- from mass air flow sensor -2<-- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) Page 1382 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Service and Repair Horn Switch: Service and Repair Horn Contact Plate, Removing And Installing Removing - Disconnect battery. - Remove driver's airbag. - Remove screws -arrows-. - Disconnect electrical connection and remove contact plate. NOTE: - Ensure metal contact surfaces of contact plate as well as contact pins in steering wheel -arrowsare clean to metal. Installing - Install in reverse order of removal. - Reconnect battery. Page 5024 - Self adhesive Bond to gear lever housing 12. Gasket - Between selector cables and gear lever housing 13. Selector housing 14. Gasket - Self adhesive - Bond underneath gear lever housing 15. Cover plate 16. Hex combi bolt, 25 Nm Fig. 1 Separating cover from gear shift knob and assembling to gear shift knob - Turn boot inside out. - Carefully pry segment with a screwdriver in direction of arrow and simultaneously pull gear shift knob out. Installation is carried out in the reverse sequence. Also, note the following: Insert gear shift knob in cover. - Push sleeve onto gear shift knob and engage. - Install gear shift knob and boot together. Specifications Clutch Fluid: Specifications Hydraulic clutch Brake fluid For further specifications refer to Brakes and Traction Control. Page 2932 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 1065 - Once seated, secure switch by turning clockwise 45°. Note: The above action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate, as well as locks in the plunger adjustment against the brake pedal. CAUTION: When installing, switch must be rotated until it is fully locked and the electrical connector is in the horizontal position. Inspect to ensure internal stop pin on retaining collar is fully seated against outer shell. - Reconnect electrical connector to switch. - Check function of brake light switch. Page 1529 Diagrams/Electrical Diagrams/Master Diagram Index Diagram 70/4 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Page 5243 Test Step 12 With Manufacturer's Scan Tool Vehicle Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Vehicle Speed Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V - Speedometer OK Test sequence NOTE: To check the speed signal the vehicle must be driven. To do this a second person is necessary. WARNING! Secure scan tool to rear seat and operate from this position. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -5- to input display group number 5 (005) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 5 -> 1234 Page 4219 Page 1361 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 1813 Relay Arrangements On The Relay Panel Page 211 - Apply adhesive tape to instrument panel in area of switch. - Carefully release switch -2- (or switch -3- ) using a knife tip or a flat screwdriver -1- and remove. - Disengage and disconnect electrical harness connectors if necessary Installing - Connect and engage electrical harness connectors. - Insert switch -2- (or switch -3-) into vent and engage. Service and Repair Transmission Cooler: Service and Repair 5 Speed Automatic 09A ATF cooler, removing and installing 1. Transmission -housing 2. O-ring - Always replace 3. ATF cooler 4. Bolt, 40 Nm 5. Dished washer - Installation position: The external diameter (contact side) faces the washer -item 6 6. Washer 7. O-ring - Always replace ATF cooler, disassembling and assembling Special tools and equipment Page 6005 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Recall 04V096000: Brake Light Switch Malfunction Brake Light Switch: Recalls Recall 04V096000: Brake Light Switch Malfunction DEFECT: The brake light switch on these vehicles may malfunction. If this happens, the brake lights could become inoperative, or come on and stay on, even though the vehicle is parked. REMEDY: Dealers will replace these switches. The manufacturer has reported that owner notification is expected to begin during April 2004. Owners may contact Volkswagen at 1-800-822-8987. Page 3360 Terminal 3 + socket 68 Terminal 4 + socket 69 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4814 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 895 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection High Pressure Sensor G65 High Pressure Sensor, Checking The following describes manual checking of High Pressure Sensor G65 using conventional measuring tools. A guided checking procedure is also possible using the VAS 5051/5052 tester in operating mode "Guided Fault Finding". Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of either G65 or F129 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Special tools, testers and auxiliary items required If performing guided test, use VAS 5051/5052 - Applicable wiring diagram - VAG 1767 Ignition tester (or equivalent device capable of duty cycle measurements) - VAG 1594/A (or C) Connector test set - VAG 1598 A Test box - In cases where refrigerant system may need to be recharged, use Kent-Moore ACR (or equivalent, VAG 1885 illustrated for reference only). Prerequisites Workshop temperature: 20-30 ° C (68-86 ° F) - Engine at workshop temperature. Preparation Note: The following test procedure is only possible on vehicles where the G65 square wave signal to Coolant Fan Control (FC) Control Module J293 is Page 5379 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 1401 - Disconnect battery ground (GND) strap. - Detach connection -2-. - Remove screws -3- and -4-. Installing - Attach crash sensor -1- with screws -3- and -4-. - Attach connector -2- to the connector housing of crash sensor -1-. - Switch on ignition. - Close all doors. - Connect battery ground (GND) strap. WARNING! No persons may be inside vehicle during this step. Diagram Information and Instructions Steering Wheel: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2857 Possible causes of malfunction if oxygen sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) - The O2S sensor has been damaged by leaded fuel Checking oxygen sensor wiring for oxygen sensor 1 - Remove wiper arms and plenum chamber cover. Page 3269 Page 4132 - With selector lever in position "1" remove solenoid with locking pin and spring from the selector lever housing. Move selector lever back and forth slightly if necessary. Installing Installation is performed in the reverse order of removal. Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Page 4121 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3065 - Spray the sensor (arrow) with commercially available chilling spray and watch the temperature value. The temperature should decrease. - End diagnosis and switch ignition off. If the intake air temperature does not drop: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Continuation of test if indication is approx. -40 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Bridge terminals 1 + 3 of connector using the respective adapter cables while observing the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 6386 Axle Beam: Service and Repair Rear Axle Beam, Assembly Overview (FWD) Rear axle beam, assembly overview Note: Welding and straightening on axle beam and stub axle is not permitted. 1. Axle beam ^ Stub axle contact surfaces and threaded holes are to be free of paint and dirt 2. Spacer bushing ^ Material: Zinc ^ Check bushing for damage 3. Coil spring ^ Application; Refer to Parts Supplier 4. Spring seat 5. Hex bolt 6. Shock absorber ^ Functional check - Item -1 7. Hex bolt ^ 40 Nm (30 ft. lbs.) plus an additional 90° - 1/4 turn ^ Always replace 8. Hex nut ^ Always replace ^ The axle beam must be in the middle position when tightening the nut ^ We recommend that the rear of the vehicle be loaded with the weight of one person when tightening 9. Hex socket head bolt, 8 Nm (70 inch lbs.) 10. Speed sensor 11. Stub axle ^ Straightening operations are not allowed! ^ Recutting the thread is not allowed! 12. Stone protection plate 13. Phillips head screw, 4 Nm (35 inch lbs.) Page 2630 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5663 8 Holding plate ^ Used to fasten the wiring harness 9 Hex nut, self-locking 20 Nm 10 Heat shield plate ^ Only on vehicles with 74 kW, 92kW, 110 kW, 150 kW engines 11 Sender -1- for Brake ^ Booster -G20112 Sensor -2- for Brake ^ Pressure -G214 13 Sealing ring ^ Replace 14 Connecting housing 15 Wiring harness 16 Vacuum hose ^ Install in brake booster 17 Sealing plug 18 Seal for brake booster 19 Hex nut, self-locking, 20 Nm 20 Boot ^ Make sure correct seat, danger of suction noises Page 2415 Radiator Cooling Fan Control Module: Electrical Diagrams For information regarding diagrams for the Coolant Fan Control, please refer to the Heating and Air Conditioning System Diagrams 38\3 to 38\5 and 39\7 to 39\8 See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Air Conditioning - Manual, From May 1999/Diagram 38\3 (Track 15-28) See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Climatronic, From May 1999/Diagram 39/7 Also Shown in Coolant System Diagrams for Vehicles With Heater Only See: Diagrams/Electrical Diagrams/Coolant Fans, From May 1999/Diagram 37\2 (Track 1-14) Page 2424 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 3676 - Carry out road test with 2nd person to observe display. Observe safety precautions when carrying out road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions - Observe figure displayed in display field 3: Specified value: approx. driven speed Display Group 005 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If no speed is displayed: - Remove wiper arms and plenum chamber cover. Page 6342 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3184 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 117 2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting of flowcharts. Condition Page 3749 Tool/Test Box, Connecting For Wiring Test Vehicles with engine code AFP - Check wire between test box socket 44 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Vehicles with engine code BDF - Check wire between test box socket 44 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Continuation for all vehicles - Also check the wire for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1162 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Page 5806 Starter Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 1304 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 1750 Warranty Required Parts and Tools Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 4210 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Brakes - Master Cylinder/ABS Pressure Testing Adapter Brake Master Cylinder: Technical Service Bulletins Brakes - Master Cylinder/ABS Pressure Testing Adapter Condition Master Cylinder / ABS, Adaptor for Checking Pressure Pressure adaptor VAG 1310/26 allows the use of VAG 1310 A to check for hydraulic pressure loss at either the master cylinder or ABS control unit. Before replacing the ABS unit due to an incorrect pressure reading when performing Leak Test, check brake fluid pressure at the master cylinder and ABS unit as follows: 47 06 01 Aug. 28, 2006 2002320 Supersedes T.B. Group 47 number 01-01 dated January 4, 2001 due to updated information. Technical Background Introduction of adaptor to allow pressure testing of brake hydraulic system. Production Solution No production change required. Service Pressure Leak Test Obtain special tools: - VAG 1310/26 Pressure Adaptor - VAG 1310 A Brake Pressure Gauge Use VAG 1310/26 with VAG 1310 A to measure hydraulic brake pressure at master cylinder and ABS unit as follows: - Remove brake lines at either master cylinder port (A or B). Install VAG 1310/26 at port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". Brake fluid pressure can also be checked at the ABS unit: - Disconnect brake lines from ABS unit to disc brake calipers (1-4), one at a time. Page 4562 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Hydraulic System Overview Clutch Master Cylinder: Service and Repair Hydraulic System Overview 5 Speed Manual 02J Hydraulic System, Assembly Overview 1. Brake fluid reservoir 2. Supply hose 3. Master cylinder - Removing and installing. 4. Retainer - Replace only with master cylinder removed - Removing refer to Fig. 1 - Pressing on refer to Fig. 2 5. Clutch pedal - Removing and installing. 6. Self-locking hexagon nut, 25 Nm (18 ft. lbs.) - Always replace 7. Seal - Pull onto line/hose connection - Insert with brake fluid 8. Line/hose assembly Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 2007 3391 - Camshaft Alignment Tool T 40005 - Audi Cam Align. Tool Page 2716 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Replacing Engine Control Module (ECM), Replacing Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Removing - First print out control module identification and thereby previous control module coding as follows: - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. The control unit identification and coding are indicated on the display, e.g.: 021906018B MOTRONIC ME7.1 G V06 -> Coding 00000 WSC 00000 - Print out control module identification by pressing scan tool PRINT button. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove wiper arms and plenum chamber cover. - Release harness connector from control module and disconnect. - Press retaining tab (arrow) to left and remove control module. Installing - Place new control module into retaining frame. - Install control module harness connector and lock. - Check previous coding and coding of new control module. - Adapt ECM to immobilizer. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt new control module to throttle valve control module. - Activate cruise control system. - Check idle speed. - Generate readiness code. Page 4066 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 1299 Part 1 Wheel Speed Sensor on Front Axle Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Front Axle Note: Removing and installing ABS system components is identical for FS III and FN 3 brake calipers. 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant, G 000 650 2 Wheel bearing housing 3 Hex socket head bolt, 8 Nm (70 inch lbs.) 4 Splash shield 5 Hex bolt, 7 Nm (62 inch lbs.) 6 Wheel bearing ^ Replace each time after removing 7 Screw 8 Brake disc 9 Wheel hub with ABS wheel speed sensor rotor ^ Pressing out and in 10 Circlip Wheel speed sensor for front axle, removing and installing Removing ^ Raise vehicle. Description and Operation Compressor Clutch Relay: Description and Operation Compressor Clutch Engagement The compressor clutch -N25- is supplied power by the Coolant Fan Control Module -293-. This module is switched by A/C switch -E35- on vehicles with Standard Air Conditioning or the A/C Control Head -E87- in vehicles equipped with the Climatronic system. For the Coolant Fan (FC) Control Module J293 location, please see Relays and Modules - Cooling System/Radiator Cooling Fan Control Module /Locations, See: Relays and Modules - Cooling System/Radiator Cooling Fan Control Module/Locations Page 781 Wheel Speed Sensor: Locations Left Rear ABS Wheel Speed Sensor G46 - Left Rear ABS Wheel Speed Sensor Page 2845 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Continuation Page 184 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6372 - Disconnect electrical connections -arrows - Remove unit from steering wheel. Installing - Install in reverse order of removal. Page 152 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5617 Use only Volkswagen approved brake fluid CAUTION! BRAKE FLUID IS POISONOUS. BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. ^ Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper ^ With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw ^ Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle ^ Ensure that brake fluid in the reservoir is at the correct level ^ Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 1601 Clay St., Detroit, MI 48211 ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL! Brakes - Vibration/Pulsation Upon Application Brake Rotor/Disc: All Technical Service Bulletins Brakes - Vibration/Pulsation Upon Application 46 10 05 October 25, 2010 2015173 Supersedes T.B. V461002 dated February 17, 2010 to add additional models and 2011 model year applicability. Vehicle Information Condition Brake Disc, Pulsation When applying brakes at highway speeds the following symptoms may occur: Brake pedal may pulsate Vibration may be felt in vehicle body Steering wheel may shake Technical Background For brake vibration / pulsation concerns, brake disc machining is now allowed between 6 months / 6000 miles and 12 months /12,000 miles of the warranty in service date. Note Production Solution No production change required. Service Note: Procedure: Page 399 Emissions - Possible MIL ON/Cat Converter DTC's Set Catalytic Converter: Customer Interest Emissions - Possible MIL ON/Cat Converter DTC's Set 26 07 06 Sept. 13, 2007 2010271 Supersedes T.B. Group 26 number 07 01 dated Feb. 9, 2007 due to the removal of 2001-2003 2.0L (AVH, AZG, BDC) engines. Vehicle Information Condition Catalytic Converter, Replacement Guidelines Catalyst efficiency faults stored in memory (See DTC table). Technical Background Guidelines for catalytic converter replacement Page 1164 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 Brake Light Switch: All Technical Service Bulletins Electrical - Glow Plug Lamp/Brake Lights Inop/DTC P0571 94 06 07 August 1, 2006 2012628 Condition EPC/Glow Plug Light On, DTC P0571 Stored in ECM Memory and/or Lack of Brake Light Functionality Customer may state EPC/Glow Plug Light On and/or brake lights inoperative or intermittent. DTC P0571 Brake Circuit -F- Implausible Circuit stored in ECM Memory Vehicles Affected Technical Background Condition may be caused by sensitive software or improperly installed brake light switch due to imprecise repair instructions. Production Solution No production change required. Service Diagnosis If EPC light -K132- or glow plug light -K29- is ON: ^ Go to Section A. If brake lights are not operating correctly: ^ Go to Section B. Section A - EPC or Glow Plug Light ON ^ With key ON/engine OFF, depress brake pedal to verify proper brake light operation. If brake lights are not operating correctly: ^ Go to Section B. If brake lights are operating correctly: ^ Using VAS 5051/5052, check Engine Control Module (ECM) for DTC P0571. If displayed DTC is not P0571: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. If displayed DTC is P0571: ^ Print GFF log and clear DTC. Page 3144 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1523 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4845 Installation position of manual valve The manual valve -arrow- must protrude approx. 3 mm out of the valve body in position "2". Screw in two bolts to hold valve body in position and test function of manual valve: - Move selector shaft left and right and watch manual valve -arrow-. If the manual valve -arrowmoves as well, installation can be continued. - If manual valve -arrow- does not move, remove valve body again and reposition manual valve. Apply sealant D176 404 A2 to the valve body cover as follows: - Cut off tube nozzle at forward marking (nozzle approx. 3 mm diameter). - Apply sealant as shown to cleaned sealing surface of valve body cover. Bead of sealing compound must be: 3 to 4 mm thick - on inside of bolt holes -arrows-. - Install valve body cover -2-. - Tighten valve body cover bolts gradually in diagonal sequence. - Install breather cap -1- to valve body cover. - Install multi-function switch -F125-. Further installation in reverse order Check selector lever cable adjustment. - Fill transmission with ATF; check ATF level and top up if necessary. Tightening torques Page 5025 Shifter M/T: Adjustments 5 Speed Manual 02J Gear selector mechanism from 05.99, adjusting Special tools and equipment required - T10027 Pin Note: The following points are essential to ensure correct selector adjustment: Moving parts of selector mechanism and transmission elements must be in proper condition. - Selector mechanism must move freely. - The transmission, clutch and clutch mechanism must also be in proper condition. - Transmission in neutral position. - Secure locking mechanism on gear selector cable and gate selector cable by pulling forward until stop (arrow -1-) and then turning to left to lock (arrow -2-). Set selector shaft as follows: Press selector shaft down (direction of arrow -1 -). - Turn right-angle piece -A- in direction of arrow -2- when pressing selector shaft down. Page 3330 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL), Significance Malfunction Indicator Lamp (MIL), Significance If malfunctions are recognized by the Motronic Engine Control Module (ECM) -J220-, the Malfunction Indicator Lamp (MIL) will be switched on. In vehicles from m.y. 2000, this is done by a signal sent by the ECM to the instrument cluster Location of Malfunction Indicator Lamp (MIL) NOTE: The MIL can switch on in the "flashing" or "permanently on" mode. DTC memory must be checked in every case. - Flashing: There is a malfunction which can cause damage to the Three Way Catalytic Converter (TWC) if driven in this condition. In this case, the vehicle must not be driven using full performance! - Permanently on: There is a malfunction which will increase exhaust emissions. Check DTC memory of the Motronic Engine Control Module (ECM) and/or automatic Transmission Control Module (TCM). - If the MIL does not light up even though there is an engine running problem, or a customer has complained, DTC memory must be checked, because malfunctions which do not switch the MIL on immediately can also be stored. Page 1459 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3458 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 2430 Radiator Cooling Fan Motor: Testing and Inspection Coolant fans (V7 and V35), checking Special tools, equipment, test and inspection devices; required accessories - VAG 1527 B Voltage tester - VAG 1594 A auxiliary measuring tool set - Wiring diagram Test conditions - Main fuses must be OK - Thermo switch for the coolant fan (F18) OK Test sequence - Remove 3-way connector from thermo switch for coolant fan (F18). Page 2221 - Release stop teeth in chain tensioner with a small screwdriver -A-. - Press tension bar against chain tensioner and tighten chain tensioner to 10 Nm. Page 6247 Power Steering Fluid: Service and Repair Power steering fluid level, checking: Requirements: ^ Engine at normal operating temperature ^ Vehicle stationary ^ Front wheels in the straight ahead position. Inspection Service: Fluid level between "min." and "max." markings. - Top up with hydraulic oil G 002 000 if necessary. Note: If the oil level has dropped to the "min." marking, the power steering should be checked. It is not sufficient simply to top up the hydraulic oil. Specifications Flywheel: Specifications FLYWHEEL TORQUE Torque ................................................................................................................................................. .................... 60 Nm. (44 ft. lbs.) + 1/4 turn (90°) [1] [1] Always replace bolts. Page 2782 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 278 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 94 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -4-. ^ Location: Above rear glass under headliner. Antennas All models use four antennas. ^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-. - Jetta / Golf / Passat (non W8) - Antenna system ^ All models use External amplified antenna mast -1-. Page 4315 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2936 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 340 Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 2000->) Control Modules - Connector Pin-out Page 5544 Note: ^ Follow the brake lathe manufacturer's instructions for set-up and machining. ^ Wash the brake disc with a soap and water solution upon completion of resurfacing to remove all machining particles. ^ Re-measure brake disc thickness in 4 locations using either the Pro Cut disc thickness measuring tool Part No.50-902 or the Hunter disc thickness measuring tool Part No.25-99-2, to verify that minimum thickness is still exceeded. If recorded brake disc measurement is less than the minimum thickness, the brake disc MUST be replaced. Note: ^ Measure brake disc lateral run out using Pro Cut Disc Lateral run out measuring kit Part No. 50-700FC or the Hunter Disc Lateral run out measuring kit Part No.25-128-2 with a dial indicator. Run out must not exceed 0.1 mm. Page 1734 ^ Remove transmission drain plug -1- and bearing pin -2-, allow transmission to totally drain. ^ Install bearing pin -2- using new grommet. ^ Install drain plug -1-. ^ Turn bracket -A- back to original position so the selector shaft -1- can move freely. Transmission, filling: ^ ADD new transmission oil Part No. G 055 726 A2 to oil already in catch container until total volume is 1.9L (2 qt.). ^ Remove back up light switch arrow -1-. ^ Connect a rubber hose (approx. 600 mm (24 in.) long with a 10 mm (3/8 in.) diameter) to a funnel. ^ Insert hose into hole of back up light switch and fill transmission. ^ Install back up light switch. ^ Check the operation of shifter. install air filter housing. ^ Install sound insulation. 02J Manual 5 Speed Transmission, Draining and Re-filling See Repair Manual Group 34, Manual Transmission - Controls, Housing. Page 1465 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 2084 Engine Oil Pressure: Testing and Inspection Oil pressure and oil pressure switch, checking Special tools, equipment, test and inspection devices; required accessories - VAG 1342 Oil pressure tester - VAG 1527 B Diode test lamp - VAG 1594 A Supplemental measuring tool set Function of the Dynamic Oil Pressure Warning System The oil pressure switch is open without pressure and is closed when the operating pressure is reached. The oil pressure warning is actuated approx. 10 seconds after the ignition is turned on. Oil pressure warning turn-on delay: approx. 3 seconds. Oil pressure warning turn-off delay: approx. 5 seconds. Checking the indicator light for operation with oil pressure After the ignition is turned on, the indicator light (K3) in the instrument panel must light for approx. 3 seconds and then extinguish. The test ends when the engine starts running. Warning criteria Warning is provided both visually (blinking indicator light) and acoustically (buzzer sounds three times). This occurs under the following operational Page 2223 - Tighten sprockets 3 and 4 for intermediate shaft to 100 Nm. - Remove locking bracket 3406. - Check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear -Bmust be aligned with the bearing parting line (TDC cyl. 1). Install camshaft roller chain and chain tensioner with tension bar: Locations Page 3547 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. Page 4490 Fluid - A/T: Testing and Inspection 5 Speed 09A Transmission ATF, checking level and topping up Special tools and equipment - V.A.G 1306 Drip tray - V.A.G 1551 Scan Tool - V.A.G 1551/3 Cable - V.A.G 1924 Reservoir - V.A.G 1331 Torque wrench - VAS 5051 Vehicle diagnosis, testing and information system - Diagnosis cable VAS 5051/3 If ATF needs to be topped up, then only ATF with Part No. 052 990 A2 may be used Page 6123 Part 1 Locations Power Protection Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5988 Fuse arrangements in fuse holder, instrument panel left Page 3098 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Assembly Overview Brake Pedal Assy: Service and Repair Assembly Overview Brake pedal, assembly overview WARNING! The brake pedal travel must not be restricted by additional floor mats. Note: Grease all mountings before installing with grease, Part No. G 000 602. 1 Mounting bracket 2 self-locking nut ^ 28 Nm (21 ft. lbs.) ^ Always replace 3 Brake light switch ^ Before installing brake light switch, connect brake pedal to brake booster push rod. ^ Before installing, pull plunger out completely Installing: ^ Push brake pedal down as far as possible by hand. ^ Guide switch through mounting hole (only fits in one position) and secure by turning switch 90° clockwise ^ Release brake pedal. ^ Connect wiring connector. ^ Check function of brake lights. ^ Pull out brake light switch plunger to full extension. ^ Keep brake pedal in up position (IMPORTANT! hold pedal up if necessary while installing switch). Page 3345 L4 Engine W/1 Exhaust Banks & 1 Catalysts Page 2396 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection High Pressure Sensor G65 High Pressure Sensor, Checking The following describes manual checking of High Pressure Sensor G65 using conventional measuring tools. A guided checking procedure is also possible using the VAS 5051/5052 tester in operating mode "Guided Fault Finding". Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of either G65 or F129 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Special tools, testers and auxiliary items required If performing guided test, use VAS 5051/5052 - Applicable wiring diagram - VAG 1767 Ignition tester (or equivalent device capable of duty cycle measurements) - VAG 1594/A (or C) Connector test set - VAG 1598 A Test box - In cases where refrigerant system may need to be recharged, use Kent-Moore ACR (or equivalent, VAG 1885 illustrated for reference only). Prerequisites Workshop temperature: 20-30 ° C (68-86 ° F) - Engine at workshop temperature. Preparation Note: The following test procedure is only possible on vehicles where the G65 square wave signal to Coolant Fan Control (FC) Control Module J293 is Page 2274 Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure, Checking Fuel Pressure Regulator And Residual Pressure, Checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). The specified value for this test is dependent on the working pressure of the Fuel Pump (FP). This is about 3.0 bar positive pressure Recommended special tools and equipment - V.A.G 1318 pressure gauge - VAG1318/10 adapter - VAG1318/11 adapter - VAG1318/16 hose adapter - VAS5024 assembly tool for spring-type clamps Test requirements - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Delivery quantity of Fuel Pump (FP) OK, Fuel Pump (FP), checking. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Vehicles with engine code AFP Not Available For Manufacturer's Scan Tool Fuel Pressure Check Valve: Testing and Inspection Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. Page 153 Part 1 Component Locations Data Link Connector: Component Locations Airbag System Component Locations (Jetta) 1 - Airbag unit driver's side (with Airbag igniter, driver's side - N95) 2 - Airbag - Malfunction Indicator Lamp (MIL) - K75 3 - Airbag unit - passenger's side (with Airbag igniter 1, passenger's side -N131) 4 - Side airbag, - front passenger's side (with Side airbag igniter, passenger's side -N200) 5 - Rear side - airbag crash sensor, passenger's side 6 - Side curtain protection, driver's and passenger sides 7 - Side airbag - crash sensor, passenger's side - G180 8 - Side airbag crash sensor, driver's side - G179 9 - Rear side airbag crash sensor, driver's side 10 - Side airbag, front driver's side (with Side airbag igniter, driver's side - N199) 11 - Airbag Control Module - J234 12 - Data Link Connector (DLC) Page 1088 set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts information You may receive an initial allocation of parts. During the campaign launch period, parts may be blocked and released by VIN through Special Services. Refer to the VWHub for campaign parts updates. After the launch period, the block may be lifted and then parts can be ordered through your facing parts depot, Time Requirements/Reimbursement Additional Campaigns Some of the affected vehicles may be involved in an additional corrective action. Please check your OTIS View Campaign inquiry screen so that any additional required work can be done simultaneously. Campaign Verification For verification, always check the OTIS View Campaign inquiry screen The OTIS system is the only binding campaign inquiry and verification source; other sources are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as to minimize inconvenience to customers, you are urged to service each vehicle at the scheduled service appointment time, Service Help If you have a question regarding this or any other campaign, please call (800) 741-2919. Dealer Personnel information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Campaign Work Procedure Parts Page 4218 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3286 Indicated on display: Rapid data transfer HELP Select function XX Adjustments Pinion Gear: Adjustments 4 Speed Automatic 01M Drive pinion, adjusting Special tools and equipment - VW 385/17 End dimension plate - VW 387 Universal dial gauge bracket - Dial gauge Conditions: Supporting ring for drive pinion bearing is installed and secured. - Parking lock mechanism and parking lock gear are installed. Adjusting: - Place two shims (each 1.5 mm thick) -arrow- onto drive pinion. - - Place output gear with tapered roller bearing onto drive pinion and tighten hex nut (41 mm AF) to 250 Nm; engage parking lock when performing this step. Page 3130 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Engine - Rattling Noise On Start Up (Normal Condition) Timing Chain Tensioner: Technical Service Bulletins Engine - Rattling Noise On Start Up (Normal Condition) Condition Camshaft Chain Tensioner(s) or Camshaft Adjuster(s), Rattle or Knocking Noise 15 06 01 Oct. 24, 2006 2012988 Technical Background The camshaft adjustment is hydraulically actuated and controlled by the engine oil pressure. If the vehicle has been sitting, with the engine turned off for a period of time, the oil accumulation inside the camshaft adjusters partially bleeds off and the oil flows back into the oil sump. To ensure an efficient camshaft adjustment after an engine cold start, the oil pressure inside the camshaft adjusters must be built up as quickly as possible. During this time a slight rattle or knocking noise may be audible. This noise is normal at engine start and will last until the oil pressure is fully reinstated. Production Solution No production change required. Service DO NOT replace the Camshaft Tensioner(s) or Camshaft Adjuster(s) for the noise concern as described above. Tip: Replacing the Camshaft Tensioner(s) or Camshaft Adjuster(s) will not eliminate this noise. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Always see ETKA for the latest part(s) information. Page 259 Volkswagen Canada, Inc. Page 3122 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 668 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3168 - Check voltage supply of Engine Control Module (ECM). See: Testing and Inspection/Component Tests and General Diagnostics/Engine Control Module (ECM) Voltage Supply, Checking - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes With Manufacturer's Scan Tool Throttle Valve Control Module, Checking Components of the throttle valve control module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1 - for for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for for throttle drive (power accelerator actuation) -G188NOTE: - If the throttle valve control module is replaced, the new control module must be matched to the Engine Control Module (ECM). Refer to "Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation", See: Engine Control Module/Testing and Inspection - On vehicles with an automatic transmission, the Transmission Control Module (TCM) must also be adapted. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Throttle valve not damaged or dirty. - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3 NOTE: Only gold plated contacts can be used to repair the contacts in the connector for the throttle valve control module. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-1-6- and -2- to input display group number 62 (062) and press -Q- button to confirm input. - Check angle sensor -1- for for throttle drive (power accelerator actuation) -G187- on idle speed stop in display field 1. - Check angle sensor -2- for for throttle drive (power accelerator actuation) -G188- on idle speed stop in display field 2. Page 6009 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5684 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 6185 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 3562 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Bridge harness connector terminals -1- + - 3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor - G70-, item -4-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display reads approx. 140 °C: Page 920 Solar Sensor: Service and Repair Sunlight photo sensor -G107, removing - Unclip sunlight photo sensor -1- with screwdriver. Page 5832 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 237 Part 1 Page 1968 Camshaft: Tools and Equipment VR-6 Camshaft Ruler - AST Tool # 3268 VR-6 Camshaft Ruler AST tool# 3268 Used for camshaft alignment and is applicable to VW VR-6 engines with 2 valves per cylinder. - Used for Camshaft Alignment - Applicable to all VW with VR-6 Engines with 2 Valves Per Cylinder Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2561 - Unscrew coolant pump securing bolts -1- and remove coolant pump -2 Note: To remove the coolant pump, push the engine to one side using a over if necessary. Installing Install in reverse sequence; note the following points: Moisten new O ring with coolant. - Insert coolant pump into cylinder block and tighten securing bolts to 20 Nm. - Fit pulley and tighten securing bolts to 15 Nm (11 ft lbs). - Align engine assembly mountings. Note: Torque settings for assembly mountings. - Install ribbed belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Ribbed Belt/Service and Repair - Fill with coolant See: Coolant/Service and Repair Locations Fuel Gauge Sender: Locations G - Sender for fuel gauge (fuel level sensor) Recall - Hazard Switch Replacement Technical Service Bulletin # RECALLVX Date: 050301 Recall - Hazard Switch Replacement Code: VX March 2005 Subject: 2000-2001 Model Year Golf/GTI (German built), 2000-2002 Golf/GTI (Brazilian Built) and 2000-2002 Jetta Vehicles Replace Emergency Light Switch (Hazard Switch) This is to inform you of the initiation of a safety recall involving some 2000-2002 model year Jetta, Golf and GTI vehicles. Problem Description Volkswagen has found that, in some cases the hazard switch and flasher system function in affected vehicles may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays (which occurs due to substantially increased electrical current load from higher-wattage turn signal bulbs). This may result in intermittent or inoperative turn signal and hazard flasher function. Remedial Action Replace the emergency light switch. Vehicle Identification Number Ranges Limitation of Sale or Lease of Certain Vehicles The National Traffic and Motor Vehicle Safety Act of 1966, as amended, mandates that dealers correct, prior to delively for the sale or lease, any vehicle which fails to comply with an applicable Federal Motor Vehicle Safety Standard or which contains a defect relating to motor vehicle safety. It is therefore Imperative that any vehicle in your new or used car Inventory and affected by this recall is corrected prior to delivery for sale or lease. Owner Notification Mailing Volkswagen Will notify all known owners of affected vehicles directly by first-class mail on or about March 31. 2005. A sample copy of the owner letter is shown for your information Vehicle Allocation A computer list containing the VINs including the owner names and addresses of vehicles that, according to our records, are located within your area of responsibility (AOR) and require this action to be performed will be provided under separate cover. Note: The above listing includes names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations Page 1347 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 1466 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 3703 Part 1 Page 432 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1105 - Apply adhesive tape to the instrument panel under seat heater switch -1- or the blank cover if the vehicle does not have heated seats and using a flat screw driver -A-, remove the seat heater switch or cover. - Insert assembly tool T10034 into seat heater switch opening, release the clip holding the ESP or ASR switch -2- and pull it out of instrument panel ^ Insert assembly tool T10034 into ESP or ASR switch opening, release the clip holding the emergency light switch -3- and pull it out of instrument panel. ^ Disconnect connector from the emergency light switch ^ On new emergency light switch (1J0 953 235 J 01C) reconnect connector and install switch into instrument panel ^ Reinstall ESP or ASR switch and seat heater switch into in the instrument panel and remove adhesive tape ^ Check turn signal and emergency light switch for correct operation ^ Check all turn signal and emergency light switch bulbs for illumination and replace as required ^ Destroy and properly dispose of removed part(s) Page 6266 1. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 2. Suction hose assembly with bracket 3. Pressure hose 4. Pressure switch ^ Switches at 40 bar (580 psi) ^ Tighten to 15 Nm (11 ft. lbs.) 5. Seal ^ Always replace 6. Banjo bolt ^ 30 Nm (22 ft. lbs.) 7. Seal ^ Always replace 8. Fixing screw 9. Guiding bolt 10. Hex nut 11. Rivet nut 12. Mounting bracket Pressure line (5-speed manual transmission 02J), securing Page 6453 1 - Thrust bolt E-15 2 - Support E-40 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod 5 - High pressure hose with quick release coupling Pulling out wheel bearing - Remove circlip. - Install press piece - 1 - with shoulder to bearing, press sleeve - 2 - with four stepped internal diameters to wheel bearing housing, piston cylinder - 3 - with pull rod and special nut - 4 - . - Operate pump and remove the wheel bearing. 1 - Thrust tube E-5 2 - Press sleeve E-65-1 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod Pulling off bearing inner race from hub Pressing in wheel bearing - Clean hole from wheel bearing housing Page 454 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 1837 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 4069 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3817 Leak Detection Pump: Service and Repair Evaporative Emissions System Components, Repairing 1 - O-Ring Replace if damaged 2 - Vent line Black - Make sure tight fit - From the switch valve on the fuel tank, item -10- Press release tabs on the connecting piece to remove from flange 3 - Vent line White - Make sure tight fit - From the pressure retention valve on the fuel tank, item -12- Press release tabs on the connecting piece to remove from flange 4 - Retaining screw 5 - Discharge hose Make sure tight fit 6 - Connector Black, 3-way 7 - Vacuum line Page 5776 ^ Using a screwdriver, lift cover of multi-pin connector and remove. ^ Using a small screwdriver, push purple latch in direction of arrow. Pin assignment of harness connector T25 and ABS Control Module (W/EDL) -J104 Pin Connected to component: 19 + 20 Right Front ABS Wheel Speed Sensor -G45 1 + 2 Left Front ABS Wheel Speed Sensor -G47 Interior - Steering Wheel Leather Wrap Coming Loose Steering Wheel: Customer Interest Interior - Steering Wheel Leather Wrap Coming Loose Condition Steering Wheel, Repairing Leather Wrap Steering wheel leather wrap loose. 69 06 08 Nov.16, 2006, 2010641, Supersedes Technical Bulletin Group 69 number 04-04 dated October 19, 2004 due to inclusion into ElsaWeb. Technical Background Leather wrapping coming loose at inner spokes due to poor adhesion. Production Solution No production change required. Service For Golf, GTI, Jetta, New Jetta, New Beetle, New Beetle Convertible, Passat, Passat Wagon and Touareg vehicles: - Remove steering wheel.See Repair Manual, Body Interior, Repair Group 69 For Cabrio vehicles: - Remove steering wheel.See Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48. - Cover portion of steering wheel not being serviced. Perform the following procedure to one steering wheel spoke at a time. - Gently pull back loose leather as far as possible -arrow-. - Completely cover exposed substrate with a generous amount of 3M® Super Weatherstrip Adhesive (Part No.08008). Tip: Do not allow adhesive to dry. - Using firm pressure, roll leather back in place. - Smooth leather until stress marks disappear. - Work leather at edges until properly located and visually acceptable. Page 645 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 4658 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5854 - VAS 5045 Battery filling bottle (or equivalent) WARNING! - Refer to Warnings and Safety Measures. - When checking electrolyte level with sealing caps removed, illuminate the inside of the battery housing/cells with a flashlight. - Keep open flames and sparks away. The correct battery electrolyte specific gravity is an important factor in maintaining battery performance and service life. An insufficient electrolyte level allows the cell plates to dry, resulting in a loss of battery capacity (reduced output). If the cell plates are not completely submerged by electrolyte, (sulfuric acid/water mixture) corrosion will occur on the plates, plate bridges and cell connector. Optimum battery function is not possible under these conditions and battery failure results. If electrolyte level is too high, electrolyte (sulfuric acid/water mixture) may leak out and damage the surrounding area, i.e.: plenum and engine compartment. - Switch ignition off - Check electrolyte level visually, either via charge indicator (if equipped) or from min./max. markings on battery housing. Electrolyte level reading from min./max. marking on battery housing -arrow-. - Electrolyte level must be above the minimum marking or just reach the maximum marking. If no minimum and maximum markings are visible on the battery housing (either not molded in or not visible due to installation location) or if the battery housing is black, the sealing plugs must be removed. Then determine electrolyte level by viewing inside the battery cells. - First remove plastic foil from cell caps (where applicable), being sure not to disturb plastic safety warning label on battery. - Unscrew cell caps. - Look into individual battery cells to determine electrolyte level. Page 6345 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Diagram 46/3 IMPORTANT NOTE: Page 3333 Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL), Checking Malfunction Indicator Lamp (MIL), Checking Functional check - Switch ignition on. The Malfunction Indicator Lamp (MIL) must light up. If the Malfunction Indicator Lamp (MIL) does not light up with the ignition switched on: - Check MIL lamp wiring/MIL lamp bulb using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. If the Malfunction Indicator Lamp (MIL) lights up with the ignition switched on, continue check as follows: - Start engine and run at idle. The Malfunction Indicator Lamp (MIL) must go out after a few seconds. If the Malfunction Indicator Lamp (MIL) does not go out: - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. If no DTCs are stored: - Check MIL lamp wiring using wiring diagram. If OK: - Check instrument cluster/ECM, and replace if necessary. - Check DTC memory; if necessary, repair any malfunctions and then erase DTC memory. - Read-out the readiness code. If the DTC memory has been erased or the engine control module was disconnected from permanent positive, the readiness code must be generated again. Page 5193 - With selector lever in position "1" remove solenoid with locking pin and spring from the selector lever housing. Move selector lever back and forth slightly if necessary. Installing Installation is performed in the reverse order of removal. Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Page 3294 - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Page 291 With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Page 2232 - Install chain tensioner for camshaft roller chain and tighten to 40 Nm. Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip. - Rotate crankshaft twice in engine travel direction and check timing. NOTE: Replace crankshaft main seal on lower timing cover, if necessary Page 296 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 1836 Fuse Block: Fuse and Fusible Link Locations Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1067 - Slowly release brake pedal to stop. Note: The above action automatically adjusts the switch plunger travel. - Reconnect electrical connector to switch. - Check function of brake light switch. "New style" brake light switch, removing and installing Note: The following applies only to a "new style" switch that is removed and replaced. Removing - Turn switch counter-clockwise 45° - Pull switch out from retainer mounting hole. - Dispose of switch accordingly. CAUTION: "New style" switches must NOT be reused after removal. Always replace. Installing CAUTION: "New style" switches have an internal switch mechanism that will be damaged if not installed and adjusted according to the following procedure. DO NOT depress switch plunger or otherwise rotate the retaining collar of the switch prior to installation. Brake pedal must be held in the up position (not depressed during switch installation. - Before installing, pull out plunger -arrow- completely. - Hold brake pedal in up position (against stop). - Note orientation of retainer tabs -1- and -2- on switch and carefully insert switch into retainer mounting hole. - Push switch in and seat fully into opening (pressing plunger against brake pedal to adjust). Page 1607 Spark Plug: Application and ID Engine Code AFP Spark plugs 1) VW Audi 101 000 035 AH Manufacturers Code BKR 5 EKUP Electrode gap max. 0.7 Tightening torque 25 Nm (18 ft lb) 1) Use tool T10029 for disconnecting and connecting the spark plug connector. Remove and install the spark plugs using tool 3122B Description and Operation Electronic Throttle Control Module: Description and Operation Function of the Electronic Throttle Control System In the electronic throttle control system, the throttle valve is not actuated by a cable from the accelerator. There is no mechanical connection between the accelerator and throttle valve. The accelerator position is communicated to the engine control module by two throttle position sensors (variable resistance, accommodated in a casing), which are connected to the accelerator. The accelerator position (determined by the driver) is a main input variable for the engine control module. An electric motor (throttle actuator) in the throttle valve control module -J338- actuates the throttle valve over the entire range of engine speeds and load. The throttle valve is actuated by the throttle actuator under instructions from the engine control module. When the engine is off and the ignition is turned on, the engine control module controls the throttle actuator precisely, following specifications from the throttle position sensor. That is, if the accelerator is half-way to the floor, then the throttle actuator opens the throttle valve to the same angle; the throttle valve is then opened approximately half-way. When the engine is running (under load), the engine control module can open or close the throttle valve independently of the sensor. As an example, the throttle valve can already be completely open, even though the accelerator has only been pressed half-way down so far. This has the advantage of preventing throttling loss at the throttle valve. Under certain load conditions, this also results in significantly reduced emissions and improved fuel consumption. It is wrong to believe that electronic throttle control only consists of two components. It is a system which contains all components needed to help determine, regulate, and supervise the throttle valve position (e.g. the throttle position sensor which measures the accelerator position, the throttle valve control module, the EPC indicator lamp, the engine control module). Page 1262 - Additionally, check wires all for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Heater Check Heated Oxygen Sensor (HO2S) -G39- Before Three Way Catalytic Converter (TWC), Checking NOTE: Only gold plated terminals may be used to repair the contacts in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display Read Measuring Value Block Input display group number XXX Page 4934 Special tools, testers and auxiliary items required ^ Hydraulic removal and installing tool for wheel bearing V.A.G. 1459 B ^ Piston cylinder HKZ-15 with hydraulic press piece E0-204-T ^ Removal rods E-0-217+218 ^ Special nut E-8-214 Thrust tube E-5 ^ Thrust tube E-10 ^ Press sleeve E-13-1 ^ Thrust bolt E-15 ^ Supplementary set V.A.G. 1459 B/2 ^ Bell E-40 - Lift vehicle until the load on the front axle is relieved. - Loosen 12-point nut. - Lift vehicle to installing height. - Remove wheel. The following three work steps are necessary only for vehicles with modified stabilizer bar mounting. - Loosen upper hex nuts of connecting links from left and right suspension strut. - Pull out clamp on brake hose bracket and release brake hose. - Release speed sensor wiring from front suspension strut. Page 6214 ^ Axle components have been damaged or replaced (in table) Requirements ^ Vehicle at curb weight ^ Fuel tank full ^ Spare wheel and vehicle tools are stowed at correct locations ^ Fluid reservoir for windshield/headlight washer system full. ^ Tire tread depth on each axle should differ no more than 2 mm (0.079 in.). ^ Tires inflated to correct pressure ^ Vehicle aligned, suspension bounced and rocked several times ^ Suspension, steering and linkage checked for wear and damage. ^ Test equipment properly adjusted and attached to vehicle. ^ Do not check vehicle alignment before vehicle has completed (1000 to 2000 km (600 to 1200 miles), to allow coil springs to settle. ^ Sliding plates and turntables (alignment equip.) must not touch an end stop when checking wheel alignment. ^ Adhere to alignment manufactures instructions ^ Check and calibrate alignment equipment once a year. ^ Treat alignment equipment with care. ^ Maximum wheel run-out must be compensated. Otherwise test results will not be correct. ^ Correct toe-in adjustment is not possible without wheel run-out compensation. NOTE: Carefully follow alignment manufacturer's instructions. - Install brake pedal support. - Compensate for wheel run-out - Lower vehicle and bounce Alignment, overview Work sequence must be followed! 1. Adjust camber 2. Check rear axle camber. Camber is not adjustable. 3. Check toe at rear axle, adjust if necessary Page 2672 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 5731 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 5277 Part 2 Page 5403 <-- Place electrical connector -1- into ABS control module and push in direction of -arrow 2- <-- Lock electrical connector to ABS control module by pushing latch down -arrow 3^ If applicable, reinstall secondary air relay box and reinsert harness in support clip ^ If applicable, reconnect electrical connector to brake fluid reservoir <-- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) <-- If applicable reconnect air hose -4- from secondary air pump to air filter box -5<-- Reconnect vacuum line -7- to air box (TDI vehicles only) <-- Reconnect air intake hose to mass air flow sensor and secure with clamp -3<-- Reconnect electrical connector -1- to mass air flow sensor -2^ Reconnect the ground cable (GDN) from the negative (-) battery terminal ^ In the vehicle, remove brake pedal depressor from the brake pedal ^ Proceed to Section D Section D Section D - Code ABS Control Module ^ Connect VAS 5051 to data link connector located under dash left of steering column Page 3271 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Diagram 74/3 IMPORTANT NOTE: Page 4120 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2421 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 6483 Page 490 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Measure resistance from throttle valve drive between terminals -3- and -5- Specified value: 1.0-5.0 ohms If the specified value is not obtained: - Replace throttle valve control module - J338- , item 10. Refer to "Intake Manifold Upper Section, Disassembling and Assembling" under "Fuel Delivery and Air Induction/Variable Induction System", - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt Engine Control Module (ECM) to throttle valve control module. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check accelerator pedal sensor. If the voltage supply and wiring is OK: - Replace Engine Control Module (ECM). Checking voltage supply and wiring to control module Page 2664 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 3248 Wire Terminal Extractor used for ECU and ABS harnesses on 1998-2005 Jetta and Passat. The blade of the H 4673-9 has a width of 1mm. - Made in Germany - Easy to Use Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Specifications Camshaft Bearing: Specifications Camshaft bearing cover Nut 20 Nm Page 4174 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 2864 - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -3-, and -4- to input display group number 34 (034) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 34 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by the Engine Control Module (ECM). - Check specified values in display fields 1-4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Service and Repair Parking Brake Cable: Service and Repair Parking brake cables Removing ^ Remove center console extension. ^ Release parking brake. ^ Loosen adjustment nut (arrow) until parking brake cable can be unhooked from compensator. ^ Raise vehicle. ^ Remove clip -1-. ^ Press brake lever -2- in direction of arrow and unhook brake cable -3-. ^ Unclip parking brake cable from retainer on rear axle (arrow -A-) and unhook from additional retainers (arrows). Page 5866 - Multimeter VAG 1526, VAG 1526A, Fluke 83, Volt-Amp tester Sun VAT 40 or equivalent. NOTE: - If no load voltage is to be measured with the battery installed in the vehicle, first disconnect ground strap. - Vehicle must not be started or driven (with battery to be tested) for at least 2 hours before taking measurements. - During this time, no load or additional charge is to be applied to battery. Check battery no load voltage as follows: - With battery installed and ignition switched off, check voltage between battery terminals with voltmeter. - No load voltage 12.5 volts or above: battery OK. Battery no load voltage must not be below 12.5 volts. If below 12.5 volts, recharge battery immediately. NOTE: After charging battery: - Wait two hours before taking measurements - During this time, no load or additional charge is to be applied to battery. - Again check voltage between battery terminals with voltmeter. - No load voltage below 12.5 volts: replace battery. Quick check NOTE: The following sequence of battery repair and servicing information/documentation is the most up-to-date available, and allows for quick servicing and checking of the various battery types installed. Use the quick check processes per battery type defined below using all specified special tools and equipment, then refer to the detailed battery servicing subjects that follow. Quick check - Batteries with charge indicator: Visual check of battery housing, poles and terminals. Visual check of electrolyte level and charge indicator (confirms electrolyte specific gravity and charge condition). Perform battery load test if necessary. - Batteries without charge indicator: Visual check of battery housing, poles and terminals. Visual check of electrolyte level. Check electrolyte specific gravity with appropriate tester. Perform battery load test if necessary. Specific Gravity Specific Gravity, Checking NOTE: - The following procedure only applies to batteries without charge indicator - In order to better determine a battery's overall condition, it is recommended to perform always the electrolyte specific gravity test in conjunction with the load test. See: WARNING! - Before working with electrolyte, refer to Warnings and Safety Measures. - Dispose of electrolyte (sulfuric acid) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal - The following notes and procedures must be followed to ensure correct measurements. Page 5048 - Bond to gear lever housing 12. Transmission-selector lever 13. Damper 14. Selector housing 15. Bushing 16. Bolt, 25 Nm 17. Fulcrum pin 18. Guide bushing 19. Spring - Installing = Fig. 2 20. Gate selector bracket 21. Torx screw, 5 Nm 22. Base plate - Open tabs to remove - Replace 23. Lock washer 24. Gate selector cable - On gate selector bracket - Installation position 25. Gear selector cable - Press onto gear shift guide - Installation position 26. Hex nut, 25 Nm 27. Bushing - Only fits in one position 28. Lock washer Fig. 1 Removing and installing circlip To remove and install circlip pull gear lever in direction of arrow -A- while pushing down spacer bushing onto stop with a screwdriver in arrow direction -B-. Note: Do not tilt spacer bushing when pushing down. Carefully release pressure at groove in gear lever for circlip. Fig. 2 Installing spring Page 6157 Power Distribution Relay: Locations Power Supply (Terminal 30, B+) Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2367 * Call Volkswagen Tools and Equipment Program (EQS), which is Equipment Solutions for product. Part number(s) are for reference only. Always see Parts Dept. for the latest part(s) information. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. FN 3 Front Brake Calipers Brake Caliper: Service and Repair FN 3 Front Brake Calipers Front brake calipers Notes: ^ Install all parts supplied in the repair kit. ^ New brake calipers are filled with brake fluid and are pre-bled. ^ Apply a thin coat of lubricant, Part No. G 052 150A2 to brake cylinders, pistons and seals. 1 Dust cap 2 Bleeder valve ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to threads before installing 3 Cap ^ Insert in mounting bushing 4 Guide pin, 28 Nm (21 ft. lbs.) 5 Mounting bushing ^ Insert into brake caliper housing 6 Brake caliper housing 7 Brake carrier 8 Retaining spring ^ Insert with both ends in holes in brake caliper housing 9 Piston seal 10 Piston ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to piston before installing Piston diameter: 54 mm (2. 125 inch) 11 Protective seal Master Cylinder/Brake Booster, Servicing (With ABS/EDS/ASR/ESP) Vacuum Brake Booster: Service and Repair Master Cylinder/Brake Booster, Servicing (With ABS/EDS/ASR/ESP) Note: Complete brake master cylinder and brake booster can be replaced independently of each other. 1 Brake booster ^ With wiring harness, Sender -1- for Brake Booster -G201-, Sensor -2- for Brake Pressure -G214, item 12 ^ On gasoline engines, the required vacuum is drawn at the intake manifold ^ On diesel engines, a vacuum pump is installed to generate a vacuum ^ Function testing With engine off, push brake pedal down all the way forcefully several times (this reduces the vacuum present in the equipment). - Now hold brake pedal in braking position with medium foot pressure and start engine. If the brake booster functions properly, the brake pedal now yields perceptibly under the foot (booster takes effect). ^ If there are malfunctions, replace completely. ^ Check valve (in vacuum hose) Function testing ^ Disconnecting from brake pedal ^ Removing and installing; refer to Brake Booster, Removing and Installing 2 Bracket ^ Mounted on edge of brake booster ^ Used to hold the connector housing -Item 143 Cover 4 Brake fluid reservoir 5 Sealing stopper ^ Moisten with brake fluid and press into expansion tank 6 Holding pin ^ Insert through the brake master cylinder 7 Brake master cylinder ^ Can not be repaired. Replace complete if there are malfunctions. Page 4001 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 1460 Page 4201 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. A/T - Pan Gasket Appears to be Leaking Fluid Pan: All Technical Service Bulletins A/T - Pan Gasket Appears to be Leaking Group: 37 Number: 01-01 Date: Mar. 5, 2001 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Supersedes T.B. Group Number 37 Number 00-02 to reflect new part number Condition Transmission appears to be leaking around ATF pan gasket. In most cases the leak is NOT caused by the ATF pan gasket, but by the main line pressure plug (arrow). ATF fluid flows down from main line pressure plug to pan seal, giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace with Part No: N 904 142 01 (plug with seal) - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases, a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. Page 3204 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 4995 Warranty Required Parts and Tools J104 - ABS Control Module Electronic Brake Control Module: Locations J104 - ABS Control Module J104 - ABS Control Module - in engine compartment, to left of vacuum brake booster - component of ABS Hydraulic Control Unit Page 2528 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Locations Thermostat Housing: Locations Thermostat Location - The thermostat is mounted in the housing and located on the rear of the cylinder head. Components 1. Coolant pipe - Secured to exhaust gas manifold together with heat shield. 2. 10 Nm 3. To heat exchanger 4. From heat exchanger 5. Throttle Valve Control Module -J338- Heated by coolant. Page 2166 Intake Manifold: Service and Repair Intake Manifold Lower Section, Disassembling and Assembling NOTE: For additional information regarding the Removal and Installation procedure please refer to: Vehicle /Engine, Cooling, and Exhaust /Engine / Cylinder Head Assembly /Valve Cover / Service and Repair. See: Cylinder Head Assembly/Valve Cover/Service and Repair Intake Manifold Lower Section, Disassembling and Assembling 1 - Cable Guide. Clipped onto fuel rail. 2 - 10 Nm. 3 - Fuel Rail. 4 - Supply Connection. 5 - Return Flow Connection. Page 6550 Air Door Cable: Service and Repair Temperature Flap Cable, Installing and Adjusting Cables, Installing And Adjusting Temperature flap cable, installing and adjusting Prerequisites: - Heating and ventilation controls are installed. - Connecting duct removed. Adjusting - Turn temperature rotary control knob to left onto stop. - Attach center wire of cable -1- to the temperature flap lever -2-. - Push temperature flap lever -2- to stop - arrow A- and secure outer cable -1- with clip -3-. - Turn temperature rotary control knob to left and right onto stops. - When turning the rotary control knob, both end stops must be reached. Page 4898 NOTE: - When inserting ensure wide space -a- on joint housing is aligned with narrow space -b- on hub. - Chamfer on inner diameter of ball hub (splines) faces larger diameter of joint housing. - Install ball hub; hub must be swiveled out of cage (arrows) far enough to allow balls to fit in ball tracks. Constant velocity (CV) joint, checking - Press cage firmly (arrow) until hub swings fully in position. CV joint is correctly assembled when ball hub can be moved by hand back and forth over its entire axial range. Page 309 Page 6507 - Pull off wheel bearing/wheel hub unit from stub axle. - A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Caution: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 ab. - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake disc. Capacity Specifications Final Drive Fluid: Capacity Specifications 02J Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.0 liters Transmission code: DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF Type ..................................................................................................................................................... .......................... G51 SAE 75w-90 (synthetic oil) Transmission codes: DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ..................................................................................................................................................... .......................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.3 liters Type .................................................................... ........................................................................................................... G51 SAE 75w-90 (synthetic oil) Page 4096 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Page 5712 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 186 Part 1 Page 6260 Power Steering Pump: Service and Repair Power Steering Pump W/Hydraulic Lines/Hoses, Assembly Overview I - Vehicles with power steering pump in upper area II- Vehicles with power steering pump in lower area 1. Reservoir 2. Pressure hose/line ^ Vehicles with TDI engine and air conditioner ^ Disassembling and assembling 3. Pressure hose/line ^ Vehicles with /TDI engine and no air conditioning ^ Disassembling and assembling 4. Pressure hose/line ^ Vehicles with TDI engine and air conditioning ^ Disassembling and assembling 5. Pressure hose/line ^ On 5-speed manual transmission 02J ^ Disassembling and assembling 6. Pressure hose/line ^ On automatic transmission ^ Disassembling and assembling Page 6387 14. Brake disc 15. Dust cap ^ A perfect seal is only achieved using a new dust cap. 16. Self-locking 12-point nut, 175 Nm (129 ft. lbs.) ^ Always replace 17. Wheel hub with wheel bearing ^ Always replace ^ The wheel bearing and wheel hub are installed together in a housing. ^ This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible! 18. Hex bolt, 60 Nm (44 ft. lbs.) ^ Always replace 19. Shield plate 20. Parking brake cable bracket 21. Parking brake cable 22. Hex bolt, 75 Nm (55 ft. lbs.) 23. Self-locking hex nut, 80 Nm (59 ft. lbs.) ^ Replace each time ^ When tightening nut, the axle beam must be in the horizontal position (unladened vehicle state) 24. Hex head bolt, 80 Nm (59 ft. lbs.) ^ Always replace 25. Rear axle bearing bracket ^ If possible do not loosen when removing the rear axle 26. Hydraulic bonded rubber bushing 27. Bonded rubber bushing 28. Parking brake cable clip 29. Bolt, 20 Nm plus an additional 1/8 turn 45° ^ Always replace 30. Vibration damper ^ Always replace Audio System - Poor Radio Reception Technical Service Bulletin # 9105-01 Date: 050502 Audio System - Poor Radio Reception Group: 91 Number: 05-01 Date: May 2, 2005 Subject: Radio, Reception Diagnosis Model(s): All with Premium V and VI Radio 1998 > 2006 Condition Poor radio reception. Service Procedure For concerns of poor radio reception: - Use the following as a guide for trouble shooting. Tip: This Technical Bulletin is divided into four sections: ^ Section 1: Includes antenna systems by vehicle. ^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics. ^ Section 3: Includes antenna lead diagnosis. ^ Section 4: Antenna cables Tip: ^ Perceived reception issues may be a result of environmental factors. ^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses. ^ Aftermarket window tint may interfere with reception. ^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal). Section 1 - Antenna systems by vehicle Tip: For more detail see Repair Manual Group 91- Communication of the vehicle you are working on. Passat (W8 only) Page 4840 Fig. 2 Designation of solenoid valves 1. N88 2. N281 3. N89 4. N92 5. N283 6. N282 7. N93 8. N91 9. N90 Fig. 3 Removing drain plug -arrowRemoving and Installing Valve body, removing and installing Special tools and equipment Page 2414 Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 2000->) Control Modules - Connector Pin-out Body - Sunroof Malfunctions or is Inoperative Sunroof / Moonroof Module: Customer Interest Body - Sunroof Malfunctions or is Inoperative 60 07 06 June 19, 2007 Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 4846 Valve body to transmission housing 8 Nm Valve body cover to transmission housing 8 Nm Multi-function switch -F125- to transmission 5 Nm Lever/selector shaft to transmission 20 Nm Rear transmission mounting - Replace bolts Bolts -A- 20 Nm + 90° Bolts -B- 40 Nm + 90° Engine Controls - DTC's 00545/00638 Stored Engine Control Module: Customer Interest Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 2781 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 3690 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1516 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 3733 Vehicle Speed Sensor: Testing and Inspection With Generic Scan Tool Checking Speed Signal Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Battery voltage must be at least 11.5 volts. - Speedometer -G21- must be OK. Test sequence NOTE: To test speed signal, vehicle must be driven. Doing this requires a second person. WARNING: Secure Scan Tool (ST) on the rear seat and have operated from there by second technician. - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 13: Vehicle speed". - Perform a road test, and have the 2nd person observe the indication on the display. - Check specified value of the vehicle speed: - End diagnosis and switch ignition off. If no speed is indicated: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - To measure voltage, connect multimeter between sockets 2 (Ground -GND-) +54 (speed signal) of test box. - Raise vehicle at front left. - Switch ignition on. - Rotate front wheel, and observe voltage indicated while doing so. Specified value: 0.0 to at least 4.0 V, fluctuating NOTE: The right front wheel must not turn during this, hold it steady if necessary. Page 667 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 6394 Ball Joint: Service and Repair Ball joint, removing and installing Special Tools and equipment 3283 Press ^ 3283 Press VAG 1756 Angle wrench ^ VAG 1756 Angle wrench 3287A Ball joint puller ^ 3287A Ball joint puller Page 1831 Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Page 4912 Constant Velocity Joint: Service and Repair Axle Shaft With Triple Roller Joint Servicing Special tools and equipment - VAG 1682 Pliers - 3340 Pliers - VW 411 Press tool - VW 412 Press tool - VW 426 Tube Drive axle with triple-rotor joint, servicing Page 5107 Test Step 10 - 11 Page 4800 - Test-drive vehicle and inspect transmission for signs of leakage. Page 2100 Engine Oil: Technical Service Bulletins Engine - Oils Meeting Manufacturer's Standard 17 09 07 June 30, 2009 2012855 Supersedes T.B. Group 17 Number 09-05 dated March 30, 2009 due to reorganization of attached world wide oil specifications list to eliminate confusion. Vehicle Information Condition Engine Oils Which Meet Volkswagen Oil Quality Standards VW 502 00, VW 505 01 and VW 504 00/507 00 (U.S. ONLY) Technical Background Information only. Production Solution No production change required. Service Attached is a Worldwide list of engine oils which currently meet Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00. TIP: SOME ENGINE OILS LISTED ON THE ATTACHMENT MAY NOT BE AVAILABLE IN NORTH AMERICA. Please refer to the specific Vehicle Owner's Manual, published Technical Bulletins and Fluid Capacity Charts to select the appropriate oil required for each Volkswagen vehicle. The sample list below are products generally available in the North American market that meet Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00 specification at the time of this publication. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation A/C Pressure Switch F129 A/C Pressure Switch F129 F129 has three functions: Switches the A/C clutch N25 off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged). - Switches the A/C clutch N25 off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out) - Switches on the second speed coolant fan V7 when refrigerant circuit pressure increases. Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. - A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Page 4621 - Pry seal out using a screwdriver. Do not damage selector shaft. - Drive in new seal until thrust piece contacts stop. Ensure that seal remains straight when driving in. - Install multi-function switch (F125) -3=. - Fit connector to multi-function switch - Push lever -1- onto selector shaft. - Shift selector lever from "P" to "2". - Tighten nut -arrow- to 20 Nm. - Install battery carrier. - Install battery. - Reconnect Ground strap to battery. - Enter radio code. Torque Converter Oil Seal Removing and Installing Special Tools And Equipment Page 2321 Water Pump: Tools and Equipment Water Pump Wrench AST tool# VAG 1590 Water Pump Wrench. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 4616 - Remove left wheel. - Remove sound insulation tray. - Remove left-hand sound insulation. - Turn steering to left lock. - Disconnect drive shaft from flanged shaft. - Mark installation position of ball joint bolts on left-hand control arm and remove bolts. - Remove bolts (arrows). - Disconnect left connecting link -1- from control arm and turn link upward. - Swing wheel bearing housing outward. - Guide left drive shaft -2- out between subframe and transmission. - Lift drive shaft and secure to suspension strut with wire. - Remove flange shaft securing bolts by threading two bolts into flange and counterholding flange shaft using a lever. - Place drip tray under transmission. - Remove flanged shaft with spring. - Pull flange shaft oil seal out using VW 771 and VW 771/37. Page 3529 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 2-pin harness connector using wiring diagram. Terminal -2- + socket 39 - Wire resistance: Max. 1.5 ohms - Additionally, check wires for short to one another. - Additionally, check wiring for short to battery positive (B+) or Ground (GND). Recall 04V584000: Hazard Switch/Relay Replacement Hazard Flasher Relay: All Technical Service Bulletins Recall 04V584000: Hazard Switch/Relay Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 2000-2002 Volkswagen/GTI 2000-2002 Volkswagen/Jetta 2000-2002 Manufacturer: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 04V584000 RECALL DATE: Dec 13, 2004 COMPONENT: Exterior Lighting: Hazard Flashing Warning Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 350000 SUMMARY: On certain passenger vehicles, the hazard switch and flasher system function may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays which occurs due to substantially increased electrical current load from higher wattage turn signal bulbs. CONSEQUENCE: This may result in intermittent or inoperative turn signal and hazard flasher function. REMEDY: Dealers will replace the hazard flasher switch/relay kit. The recall is expected to begin during february 2005. Owners should contact Volkswagen at 1-800-822-8987. NOTES: VW recall No. VX. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 2070 NOTE: - When installing ribbed belts that have already been used, make sure to mark the running direction when they are removed. - Before installing the ribbed belt, make sure that all subassemblies (generator, air conditioner compressor, vane pump) are tightly mounted. - When installing the belt, ensure correct seat of the ribbed belt in the belt pulleys! - Install ribbed belt. - Remove hex bolt to reapply tension to ribbed belt. - Start engine and check running of belt. - Install engine cover. - Install center and right engine compartment cover for noise insulation. Page 5769 Wheel Speed Sensor: Locations Right Front ABS Wheel Speed Sensor G45 - Right Front ABS Wheel Speed Sensor Page 5588 <-- Remove clamp -3- and disconnect intake air hose from mass air flow sensor <-- If applicable, remove secondary air hose -4- from air filter box -5<-- Remove screws -6- securing air filter box and remove air filter box ^ If applicable, remove and move aside secondary air relay box and harness from supporting clip ^ If applicable, disconnect electrical connector on brake fluid reservoir <-- Release ABS control module electrical connector by pulling latch upward -arrow 1<-- Pull electrical connector off ABS control module -arrow 2^ Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws ^ Lower vehicle ^ Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle ^ Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor ^ Raise vehicle ^ Close left front and left rear caliper bleed screws when brake fluid stops flowing ^ Lower vehicle ^ Do not remove brake pedal depressor from brake pedal at this time Note: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system ^ Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 2626 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6170 Power Distribution Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 3368 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- from Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). - Check wiring for open circuit between test box and 6-pin harness connector (to control module) according to wiring diagram. Terminal -1- + socket 70 - Terminal -2- + socket 71 - Terminal -5- + socket 51 - Terminal -6- + socket 52 - Wire resistance: Max. 1.5 ohms Page 5423 <-- Remove brake lines -3- on the side of hydraulic unit CAUTION! DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC CAUTION! MAKE SURE NO BRAKE FLUID <-- From the repair kit provided (1J0 998 375) place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates Note: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION! DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT Page 4213 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6027 Fuse Block: Service and Repair Fuse Holder on Battery, Removing and Installing Fuse Holder On Battery, Removing And Installing NOTE: Obtain connector pin assignment from respective wiring diagram! Service and Repair Oil Filter: Service and Repair For further information regarding this component please refer to Lubrication Systems; Service and Repair. Page 4791 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 5607 An initial quantity of required replacement parts (other than brake fluid) calculated according to vehicles located in your area will be shipped to you prior to the owner notification mailings. The parts are as shown. Additional required parts after depletion of the initial shipment must be ordered by you from your facing parts depot and not to exceed 50% of the vehicles left for repair according to your area vehicle allocation list. Please note: Excess parts ordered by you will either be denied shipment or requested to be returned. Parts Return All removed control units must be properly tagged with dealer number, repair order number and VIN, and immediately returned in the box of the new unit to: Volkswagen c/o 1601 Clay St. Detroit, MI 48211 ATTENTION: (Recall - WJ) Time Requirements Reimbursement To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below. Claims will only be paid for vehicles that show the WJ code in the OTIS campaign inquiry system on the day of repair. A copy of the print out must be attached and remain with your copy of the repair code. WJ Data Entry Procedure The system automatically enters the part number and labor applicable to the above listed codes. Page 4755 - Position holes -A- of turbine shaft in horizontal position. - Protect transmission by carefully taping around turbine shaft and over holes. - Saw through sleeve bearing using a saw blade. Do not saw at thrust point of sleeve bearing (arrow). Ensure that no filings enter transmission. Load Reduction Relay Power Distribution Relay: Locations Load Reduction Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Component Locations Steering Wheel: Component Locations Multi-function Steering Wheel, Overview 1 - Multi-function steering wheel With integrated control unit -E2212 - Instrument cluster Control module with display unit in instrument cluster -J285- Removing and installing instrument cluster 3 - Radio Installed in center console 4 - Control module for multi-function steering wheel -J453- Installed on 13-position auxiliary relay panel 5 - Engine Control Module (ECM) Controls cruise control Page 5402 <-- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit ^ Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION! DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE <-- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) ^ Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws Note Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation ^ Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs) Note Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean ^ Remove yellow plastic plugs and red bracket from hydraulic unit ^ Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) ^ Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on atleast2morevehicles.Only one repair kit will be allocated for every 3 vehicles ^ Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) ^ Remove lint-free clothes from under the ABS control module and hydraulic unit Page 5342 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 362 Control Module HVAC: Description and Operation A/C Control Head -E87-, Function A/C Control Head -E87-, Function 1 - Windshield defrost button 2 - Blower speed display In automatic operation - 8 -, a mid-range is displayed independent of actual blower speed. 3 - Ambient (outside) temperature display Display will not change when road speed is below 15 km/h (9.5 mph) and coolant temperature is above 70 °C (158 °F). Under these conditions the actual measured value is not shown because at low road speed the radiant heat from the vehicle engine will cause a false reading. 4 - Windshield defrost display 5 - Air recirculation display 6 - Air distribution display Function "air flow to footwell" is displayed or goes out when pressing button -14-. - Function "air flow to upper body" is displayed or goes out when pressing button -15-. 7 - Selected temperature display To change from degrees Celsius to Fahrenheit and vise versa: Press and hold button -11- and press button -9-. - Selected temperature scale appears in display. 8 - Operating mode display "AUTO": Automatic mode Page 5395 An initial quantity of required replacement parts (other than brake fluid) calculated according to vehicles located in your area will be shipped to you prior to the owner notification mailings. The parts are as shown. Additional required parts after depletion of the initial shipment must be ordered by you from your facing parts depot and not to exceed 50% of the vehicles left for repair according to your area vehicle allocation list. Please note: Excess parts ordered by you will either be denied shipment or requested to be returned. Parts Return All removed control units must be properly tagged with dealer number, repair order number and VIN, and immediately returned in the box of the new unit to: Volkswagen c/o 1601 Clay St. Detroit, MI 48211 ATTENTION: (Recall - WJ) Time Requirements Reimbursement To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below. Claims will only be paid for vehicles that show the WJ code in the OTIS campaign inquiry system on the day of repair. A copy of the print out must be attached and remain with your copy of the repair code. WJ Data Entry Procedure The system automatically enters the part number and labor applicable to the above listed codes. Page 4449 - Always replace seal (arrow) when checking ATF level. ATF LEVEL, CHECKING Checking Conditions - Transmission not in emergency run mode, ATF temperature not above approx. 30° C (86° F). - Vehicle level. - Selector lever in "P". - Remove noise insulation tray. - Remove noise insulation from left long member. - Attach VAG 1924 ATF filling system reservoir to vehicle. - Connect VAG 1 551 scan tool and enter address word "02 Transmission electronics". Advance until "Select function XX" is indicated on display. - Start engine. - Raise vehicle. - Place container under transmission. Page 3815 - Use wiring diagram to check cable between contact 3 of 3-terminal plug and relay plate for broken connections. Line resistance: 1.5 Ohms maximum If the LED illuminates (power supply OK): - Remove windshield wiper arms and cowl: - Connect VAG 1598/31 test box to control module wiring. - Use wiring diagram to check cables between test box and 3-terminal plug for any broken connections. Contact 1 + cavity 80 - Contact 2 + cavity 25 - Line resistance: 1.5 Ohms maximum - Also check cables for short circuits between each other. Specification: Infinity Ohms If no fault could be detected in the cables and there was voltage between contact 3 + ground: - Replace leak detection pump (V144), item -8-. - Read-out readiness code: - If fault memory has been erased or engine control module was separated from positive voltage supply, readiness code must be regenerated: Checking resistances Test sequence - Remove rear right Fender liner: Page 5677 Volkswagen Canada, Inc. Page 1622 6800TDI - TDI Timing Belt Tool Set Additional Tools Possibly Required: 3359 - TDI Lock Pin EPC Warning Lamp Page 869 Part 2 Description and Operation Discharge Air Temperature Sensor / Switch: Description and Operation Footwell air outlet temperature sensor -G192- (Vehicles with Climatronic) Function: Controls air distribution defrost/footwell and fresh air blower speed depending on air outlet temperature measurement. Emergency running in event of failure: Continued operation assuming value of +80 °C (176 °F) Page 2011 Crankshaft: Tools and Equipment Crankshaft Counter-hold - AST Tool # 3415 Crankshaft Counter-hold AST tool# 3415 Required to lock spur belt sprocket on most 4 cylinder water cooled inline VW/Audi engines, including engines equipped with aluminum oil pan. Used to counter hold crankshaft toothed belt sprocket when replacing the crankshaft oil seal. Accessory pin design also allows holding of some cam or counter shaft gear sprockets. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Service and Repair Air Cleaner Housing: Service and Repair 1 - Harness connector Black, 2-pin - For Positive Crankcase Ventilation (PVC) heating element -N79- Check heater element voltage supply between terminals 1 and 2 with engine running: - Specified value: at least 11.5V 2 - Connecting hose For air circulation of fuel injectors 3 - Intake hose Note installation position 4 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-* Checking -G70-. Refer under "Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor", See: Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor/Testing and Inspection - Checking - G42-. Refer under "Powertrain Management/Computers and Control Systems/Air Temperature Sensor", See: Powertrain Management/Computers and Control Systems/Intake Air Temperature Sensor/Testing and Inspection - Sensor and harness connector terminals are gold plated 5 - Harness connector Black, 5 pin - Sensor and harness connector terminals are gold plated 6 - Seal Always replace if damaged 7 - Air cleaner upper section Keyless Entry/Starting - Remote Key Inoperative Keyless Start Transmitter: Customer Interest Keyless Entry/Starting - Remote Key Inoperative 57 08 10 Oct. 28, 2008 2011385 Supersedes T.B. Group 57 number 08-08 dated May 20, 2008 due to addition of 2009 CC. Vehicle Information Condition Remote Control Key Diagnostics ^ Remote control key is inoperative, or has inconsistent operation. ^ Only Lock button on remote control key functional ^ DTC 00956 005, No or Incorrect Basic Settings/Adaptation may be present. Technical Background Proper diagnosis of remote control key functionality is critical before replacement of remote. Production Solution No production change required. Service Page 6106 Relay Arrangements On The Relay Panel Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Fuse Arrangements In Fuse Bracket/Battery Page 5249 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 3894 Fuel Injector: Vehicle Damage Warnings When working on the fuel supply and fuel injection system, pay careful attention to the following five rules of cleanliness: - Thoroughly clean all unions and adjacent areas before disconnecting. - Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths! - Carefully cover or seal opened components if the repair cannot be carried out immediately. - Only install clean components: only unpack replacement parts immediately prior to installation. Do not use parts that have been stored loose (e.g. in tool boxes etc.). - When the system is open: do not work with compressed air (if this can be avoided) and do not move vehicle unless absolutely necessary. Page 4358 - Moisten sealing lips with ATF before installing - Turn cap slightly when installing 11. Intermediate spring ring - With spring supporting shell and compression springs 12. Piston - Sealing lips are vulcanized to piston - Moisten sealing lips with ATF before installing - Turn piston slightly when installing 13. Clutch housing - Before inserting the inner plate carrier corrugated washer (item 8), insert inner and outer plates in the clutch see Fig. 3 Fig. 1 Removing and installing circlip - Press piston cap with intermediate spring ring down far enough for circlip (arrow) to be inserted in groove. Fig. 2 Installing thrust plate and plates onto inner plate carrier - Install thrust plate -a- with smooth side facing inner plate and stepped side towards inner plate carrier. - Install 3 inner plates -b- and 2 outer plates -c-. - Clip in supporting ring with step (arrow). Note: Locate tabs correctly. - Installing corrugated washer and further plates in clutch housing. Page 1906 Wheel Bearing: Service and Repair Rear Wheel Bearings, Servicing Wheel bearings, servicing Wheel bearings, vehicles with front wheel drive, servicing Note: The descriptions and illustrations are for vehicles with disc brakes. - Wheel fittings for vehicles with drum brakes is the same. - All tightening torques and notes are therefore valid for vehicles with drum brakes. 1. Phillips-head screw 2. Brake disc 3. Dust cap - Always replace A perfect seal is only achieved using a new dust cap. Only then is an optimum function and long service life guaranteed. 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace 5. Wheel hub with wheel bearings The wheel bearing and wheel hub are installed together in housing. This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible! 6. Axle beam Page 3281 - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. - The -> button is used for advancing through the program sequence. - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Connecting VAS 5051 Special tools and equipment Page 1021 Note: Make certain the brake light switch is installed with the wiring harness connector housing pointing upward. ^ Secure the brake light switch and plunger position by slowly turning the brake light switch full to the right (clockwise) 45 degrees, and the internal stop pin of the brake light switch is fully seated at the end of slot in outer shell. Tip: A click should be heard when the switch is turned to the correct position. This action also turns the plunger shoe into the correct position to make the correct electrical contacts in the switch operate as well as locks the plunger adjustment. ^ Internal stop pin (white arrow) of the brake light switch is fully seated at the end of the slot in the outer shell (black arrow) when brake light switch is correctly installed. ^ Reconnect brake light switch wiring harness connector. If the EPC or glow plug light was blinking and there was a diagnostic code (DTC) stored in the Engine Control Module and the DTC was related to the brake light switch: ^ Connect the VAS 5051/5052 to clear DTC. ^ Create engine readiness code. ^ Depress brake pedal to verify proper function and brake light operation. ^ Install cover under dashboard. Part return pertains to U.S. vehicles ONLY ^ When requested by WTC, return all brake light switches replaced to the address below. Include a copy of the repair order, all diagnostic printouts, and any other related documentation. Volkswagen of America, Inc. Warranty Test Center 3800 Hamlin Rd. - GE01 Auburn Hills, MI 48326 Page 6545 Air Door Cable: Adjustments Temperature Flap Cable Cables, Installing And Adjusting Temperature flap cable, installing and adjusting Prerequisites: - Heating and ventilation controls are installed. - Connecting duct removed. Adjusting - Turn temperature rotary control knob to left onto stop. - Attach center wire of cable -1- to the temperature flap lever -2-. - Push temperature flap lever -2- to stop - arrow A- and secure outer cable -1- with clip -3-. - Turn temperature rotary control knob to left and right onto stops. - When turning the rotary control knob, both end stops must be reached. Page 6341 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4697 Part 1 Page 2992 Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure, Checking Fuel Pressure Regulator And Residual Pressure, Checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). The specified value for this test is dependent on the working pressure of the Fuel Pump (FP). This is about 3.0 bar positive pressure Recommended special tools and equipment - V.A.G 1318 pressure gauge - VAG1318/10 adapter - VAG1318/11 adapter - VAG1318/16 hose adapter - VAS5024 assembly tool for spring-type clamps Test requirements - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Delivery quantity of Fuel Pump (FP) OK, Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Vehicles with engine code AFP Page 3520 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. Page 1502 Page 519 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3261 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5835 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Specifications Oil Pressure Sender: Specifications Switch - Tightening Specifications Switch - Tightening Specifications 0.3 Bar Switch (Brown) 20 Nm 1.4 Bar Switch (Black) 25 Nm Page 176 Installing - Installation is reverse of removal. Page 2459 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 363 - In automatic mode the Climatronic maintains the selected inside temperature automatically. With this setting, the air outlet air temperature, the blower speed and the air distribution are controlled automatically. "ECON": A/C system off In ECON mode only the compressor is switched off. Heating and air distribution continue to be controlled automatically. "OFF": Complete system is switched off Switch off with button -17-. - In this mode, all flaps remain in the last set position before switching off. (Setting should only be used in case of a malfunction). 9 - Automatic operation button 10 - Instrument panel interior temperature sensor -G56- and interior temperature sensor fan -V42- Installation position for right-hand drive vehicles. 11 - "ECON" button In ECON mode only the compressor is switched off. The heater and air distribution continues to be controlled automatically. 12 - "Warmer" button 13 - "Colder" button 14 - "Air flow to footwell" button 15 - "Air flow to upper body" button 16 - "Increase blower speed" button 17 - "Decrease blower speed" button To switch off A/C system press and hold button until "OFF" appears in display. - In this mode, all flaps remain in the same position before switching off. (Setting should only be used in case of a malfunction) 18 - Recirculating air button 19 - Instrument panel interior temperature sensor -G56- and interior temperature sensor fan -V42- Installation position for left-hand drive vehicles. Page 4324 - With selector lever in position "1" remove solenoid with locking pin and spring from the selector lever housing. Move selector lever back and forth slightly if necessary. Installing Installation is performed in the reverse order of removal. Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Page 3893 WARNING! - Test and measuring instruments must be secured to the rear seat and operated by a 2nd person from this location. - If test and measuring instruments are operated from thee front passenger's seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries if the airbag is triggered. Specifications Wheel Fastener: Specifications Wheel bolts to wheel hub for all vehicles ............................................................................................................................................ 120 Nm (88 5 ft. lbs.) Tires - Vehicle Inspection After A Blowout Technical Service Bulletin # 4401-02 Date: 010627 Tires - Vehicle Inspection After A Blowout Group: 44 Number: 01-02 Date: June 27, 2001 Subject: Inspecting Surrounding Area on Vehicle for Damage if Customer Has Experienced a Tire Blow-Out Model(s): All Supersedes T.B. Group 44 number 01-01 dated Apr. 24, 2001 Service If a customer has experienced a tire blow-out or has operated the vehicle with a deflated tire until it is severely damaged or destroyed: - Inspect the wheel well and surrounding area for damage to parts such as the wheel liner, ABS sensor wires (if equipped), brake lines, hoses, etc which a damaged tire may have caused. - In addition, if the affected tire is the right rear tire, make sure to inspect the fuel tank and filler neck for abrasion damage and leakage. - Repair any damage found or damaged part. - Report all tire related fuel system damage to The Volkswagen Technicians Helpline at 1-800-678-2389. - Refer to the customer letter as shown for additional information. Page 5992 S164 - Fuse -3- (30) in fuse bracket/battery S176 - Fuse -4- (30) In Fuse Bracket/Battery S176 - Fuse -4- (30) in fuse bracket/battery S177 - Fuse -5- (30) In Fuse Bracket/Battery Page 542 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 4781 Part 1 Page 3350 Display Group 036 If the specified value is obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 204 Part 1 Specifications Valve Clearance: Specifications Valve clearance Less than 0.2 mm more than 0.1 mm Page 939 Dimmer Switch: Service and Repair Headlight Adjuster -E102*- With Instrument Panel Light Dimmer Switch -E20-, Removing And Installing Removing - Protect instrument cluster around cover with adhesive tape if necessary. - Release switch housing from installation frame carefully using a flat point screwdriver. Pull out. - Disconnect electrical connector. Installing - Connect electrical connector. - Insert headlight adjuster in guide on mounting frame and press in. *) Where applicable Page 6506 Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove securing bolts - A - from brake caliper. - Remove brake caliper and hang up on body. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove 12-point nut. Service and Repair Steering Angle Sensor: Service and Repair Electronic Stability Program (ESP) Following steps are valid only for vehicles with Electronic Stability Program (ESP). Vehicles with ESP are additionally equipped with a Steering angle sensor -G85-. sensor is installed in conjunction with coil connector and slip ring in a housing. Removing - Front wheels and steering wheel must be in straight-ahead position. NOTE: Replacement slip ring is secured as a new part in center position with cable tie Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - Disconnect steering angle sensor connection. - Lift hooks - arrows - carefully and remove steering angle sensor. Installing - Install in reverse order of removal. For vehicles with ESP observe following: When installing, ensure steering angle sensor is correctly seated and is free of stress. - Front wheels and steering wheel must be in straight ahead position. - Remove transportation protection (cable tie) on markings before installing a new steering angle sensor. - Install steering angle sensor, until lugs engage. - Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - A zero compensation must then be performed. Page 737 - Lock catches - arrows - of micro-switch - 1 - into lock cylinder housing - 2 -. - Make sure that micro-switch is positioned with securing tabs - arrows - on lock cylinder housing 1 -. - Before locking micro-switch, if must be checked that wires are lying correctly in retaining profile of micro-switch and lock cylinder. If this is not case and micro-switch is locked, wires/micro-switch may be damaged. - Lock micro-switch - 1 - with lock cylinder housing - 2 -. Make sure that catch - arrow - is engage correctly. - Install lock cylinder housing. Page 4431 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1043 ^ This switch can be identified by the larger (approx. 10 mm) plunger tip and square shaft (arrow). - Remove brake switch by turning left 90° Install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511D: Installing below). Brake switch, Part No: 1J0 945 511B, C or D, removing: ^ These switches can be identified by the smaller (approx. 4 mm) plunger and round shaft (black arrow). - Remove brake switch by turning left 45° When replacing after removal, install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511 D: Installing below). 2. Brake switch, Part No: 1J0 945 511 D: Installing: CAUTION! This version switch contains an internal switch which can be damaged if not installed and adjusted properly. DO NOT depress plunger prior to installation. Page 2329 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 3377 Wiring Test - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. - Check wires between test box and 6-pin connector (to control module) for open circuit according to wiring diagram. Terminal 1 + socket 70 Terminal 2 + socket 71 Terminal 5 + socket 51 Terminal 6 + socket 52 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7, - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 6544 Air Door Cable: Adjustments Footwell/Defroster Flap Cable Cables, Installing And Adjusting Footwell/defroster flap cable, installing and adjusting Prerequisite: - Heating and ventilation controls are installed. Adjusting - Turn air distribution rotary knob to left to stop. - Attach wire end of cable -1- to temperature flap lever -3-, arrow -A-. - Push footwell/defroster flap lever to stop -arrow C- and attach outer cable -1with clip - 2-, -arrow B-. - Turn air distribution rotary control knob to left and right to stops. - When turning the rotary control knob, both end stops must be reached. Page 1256 If the specified value is obtained: - Change to display group 32 as follows: - Press -C- button. - Press buttons -0-, -3- and -2- to input display group number 32 (032) and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 32 -> 12 - Check oxygen sensor control learned value at idling (additive) in display field 1. - Check oxygen sensor control value at part load (multiplicative) in display field 2. Page 4837 Fig. 9 Installing valve body - Route conductor strip as illustrated. When installing do not kink or twist. Fig. 10 Installing ATF screen - Before installing ATF screen insert seal in valve body. - Firmly press ATF screen onto valve body. Fig. 11 Installing securing clip with bolt for conductor strip connector - Connect conductor strip connector to lower retainer. - Fit upper retainer with recess (arrow) onto connector tab. - Tighten bolt to 20 Nm. Page 5520 ^ Remove both guide pins (arrows) from brake caliper. ^ Remove brake caliper housing and secure with wire so that weight of brake caliper does not stress or damage brake hose. ^ Remove brake pads from brake caliper housing or from brake carrier. ^ Clean brake caliper housing, especially bonding surface for brake pad. Surfaces must be free of adhesive or grease residue. Installing Brake pads with specified direction of rotation 1 - Right-hand side piston brake pad 2 - Left-hand piston side brake pad with pad wear sensor 3 - Pad wear sensor connector Note: Before inserting new brake pads, press the piston back into the cylinder with the piston resetting tool. Before pressing the piston back, draw off brake fluid from the brake fluid reservoir with a bleeder baffle. particularly if reservoir has been topped up, fluid will overflow and cause damage. Page 4366 Fig. 3 Installing corrugated washer and inner and outer plates in clutch housing - First insert corrugated washer. - Insert 2 mm thick outer plate. - Insert remaining inner and outer plates. Fig. 4 Inserting inner plate carrier and installing circlip (arrow). - Lift inner plate carrier slightly to install circlip (arrows). FN 3 Front Brake Calipers Brake Caliper: Service and Repair FN 3 Front Brake Calipers Front brake calipers Notes: ^ Install all parts supplied in the repair kit. ^ New brake calipers are filled with brake fluid and are pre-bled. ^ Apply a thin coat of lubricant, Part No. G 052 150A2 to brake cylinders, pistons and seals. 1 Dust cap 2 Bleeder valve ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to threads before installing 3 Cap ^ Insert in mounting bushing 4 Guide pin, 28 Nm (21 ft. lbs.) 5 Mounting bushing ^ Insert into brake caliper housing 6 Brake caliper housing 7 Brake carrier 8 Retaining spring ^ Insert with both ends in holes in brake caliper housing 9 Piston seal 10 Piston ^ Apply thin coat of assembly lubricant G 052 1 50 A2 to piston before installing Piston diameter: 54 mm (2. 125 inch) 11 Protective seal Testing and Inspection Fuel Tank Pressure Release Valve: Testing and Inspection Fig. 2 Switch valve, check Lever in rest position: closed Lever pressed in direction of arrow: open NOTE: Remove the fuel tank cover before installing the switch valve. A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools With Manufacturer's Scan Tool Vehicle Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Vehicle Speed Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V - Speedometer OK Test sequence NOTE: To check the speed signal the vehicle must be driven. To do this a second person is necessary. WARNING! Secure scan tool to rear seat and operate from this position. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -5- to input display group number 5 (005) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 5 -> 1234 With Manufacturer's Scan Tool Intake Air Temperature Sensor: Testing and Inspection With Manufacturer's Scan Tool Intake Air Temperature Sensor -G42- Checking NOTE: The Intake Air Temperature (IAT) sensor -G42- is a part of the Mass Air Flow (MAF) sensor -G70- and cannot be replaced separately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram - VAG1921 hose clip pliers - Chilling spray (commercially available) Test sequence NOTE: Only gold plated contacts must be used to repair The contacts in the intake air temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read intake air temperature value in display field 4. Page 4921 - Raise vehicle further to relieve coil spring pressure. - Remove wheels. - Unclip brake cable (arrows). - Remove clips -2- on both sides. - Disconnect brake lines. - Remove brake caliper housing bolts -A-. - Remove connector -1- from speed sensor. - Unclip speed sensor wiring from retainer. - Support rear axle. For example, with transmission jack VAG 1383 A A/T - Leaks Near Pan Seals and Gaskets: By Symptom A/T - Leaks Near Pan Group: 37 Number: 00-02 Date: Dec. 22, 2000 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Condition Transmission appears to be leaking around ATF pan. In most cases the leak is NOT caused by the ATF pan gasket but by the main line pressure plug (arrow). ATF fluid flows down from the main line pressure plug to the pan seal giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace seal, Part No: N 013 811 5 - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. - Test drive vehicle and inspect transmission for signs of leakage. Page 3706 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Load Reduction Relay Power Distribution Relay: Locations Load Reduction Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 20 - Press button -3- (to advance to display group 2 3). - Indicated on display (example only) Read Measuring Value Block 23 -> 101 If something different appears on the display, perform "adapting ignition keys" function. If a "0" is displayed in display field 3: An ignition key with an incorrect type of transponder was used. - Obtain key with correct type of transponder. NOTE: - Various types of ignition keys with various types of transponders are available. Observe when ordering parts!. - Press -> button to return program to function selection. Indicated on display Rapid data transfer HELP Select function XX End Output (Function 06) End Output (function 06) - Press buttons -0- and -6- to select function 06, "End Output". Indicated on display Rapid data transfer Q 06 - End Output - Press -Q- button to confirm input. Indicated on display Rapid data transfer Help Enter address word XX - Switch ignition off and disconnect Data Link Connector (DLC). Emergency Start Function, Activating Without VAG 1551 Emergency Start Function, Activating Without VAG 1551 Using the emergency start function, a vehicle with a faulty anti-theft immobilizer can be started and driven under its own power to a VW dealership. Requirements - Customer must provide proof of authorized vehicle operation/ownership with vehicle documents and identification - Key tag with covered secret number is available (If not, See "Determining secret number". - Mechanically correct key available - Switch ignition on. - Press reset button for trip odometer counter in and hold for 10 seconds. In the display for the trip odometer counter "0000" appears and the first digit blinks. Using the reset button for the trip odometer counter, the first digit can now be moved from "0" through "9": - Press reset button for trip odometer counter until valid first digit of secret number is displayed, e.g. "5" Page 5102 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 1580 Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure, Checking Fuel Pressure Regulator And Residual Pressure, Checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). The specified value for this test is dependent on the working pressure of the Fuel Pump (FP). This is about 3.0 bar positive pressure Recommended special tools and equipment - V.A.G 1318 pressure gauge - VAG1318/10 adapter - VAG1318/11 adapter - VAG1318/16 hose adapter - VAS5024 assembly tool for spring-type clamps Test requirements - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Delivery quantity of Fuel Pump (FP) OK, Fuel Pump (FP), checking. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Vehicles with engine code AFP Page 4628 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 5082 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Ribbed Belt, Removing and Installing Ribbed Belt: Service and Repair Ribbed Belt, Removing and Installing Ribbed Belt, Removing And Installing NOTE: - Always replace ribbed belt if found to be faulty. This will avoid related break-downs or operating problems. - If a used ribbed belt is to be reused, mark direction of rotation before removing. When installing used ribbed belts observe the direction of rotation marked on removal. Installing opposite to the direction of rotation leads to belt damage - It is not necessary to adjust the ribbed belt tension, as a spring loaded tensioner guarantees the best possible belt tension Preparation, all engines - Remove securing bolts -arrows- and remove the middle cover of the engine compartment noise insulation. - Remove hex nut, unclip securing clips -arrows- and remove right-hand engine cover of the compartment noise insulation. All gasoline engines, continued: - Mark direction of rotation of ribbed belt if it is to be reused. Page 3902 Fuel Injector: Testing and Inspection Fuel Injectors, Checking With Manufacturer's Scan Tool Fuel Injectors, Checking Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VAG1527B voltage tester - VW1594 adapter set - Wiring diagram Test requirements - Fuses 28 and 32 OK - Engine speed sensor OK (checking). Refer under "Powertrain Management/Computers and Control Systems/Engine Speed Sensor", See: Computers and Control Systems/Engine Speed Sensor/Testing and Inspection - Battery voltage at least 11.5 V - Fuel pump relay OK Test procedure WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. - Remove intake manifold upper section. NOTE: Seal the intake ports in the intake manifold lower section or in cylinder head with a clean cloth. - Disconnect harness connectors from fuel injectors. Checking resistance of fuel injectors Page 5142 Part 2 Page 2883 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes 4 Speed Automatic 01M Shifter A/T: Service and Repair 4 Speed Automatic 01M Servicing Selector mechanism, servicing Special tools and equipment V.A.G 1331 Torque wrench - Feeler gauges WARNING: Before working on the engine when it is running, move the selector lever into position "P" and apply the parking brake. Selector mechanism, checking Selector lever in "P" position and ignition switched on: Brake pedal not depressed: Selector lever is locked and cannot be shifted out of "P" position. Shift lock solenoid blocks selector lever. Brake pedal depressed: Shift lock solenoid releases selector lever. It is possible to shift into a driving range. Selector lever in "N" position and ignition switched on: Brake pedal not depressed: Selector lever is locked and cannot be shifted out of "N" position. Shift lock solenoid blocks selector lever. - Brake pedal depressed: Shift lock solenoid releases selector lever. It is possible to shift into a driving gear. Note: The starter must not operate in the selector lever positions "1" "2" "3" "D" and "R". - When travelling at speeds above 5 km/h and shifting into selector lever position "N" shift lock solenoid must not engage and block selector lever. Selector lever can be shifted into a driving gear. - When travelling at speeds below 5 km/h (almost stopped) and shifting into selector lever position "N" shift lock solenoid must not engage until after approx. 1 sec. Selector lever cannot be shifted out of "N" position until brake pedal is depressed. Removing and Installing Selector lever, removing and installing - Obtain radio code on vehicles with coded radio. - Disconnect battery ground strap. Removing Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Disconnect locking cable from the selector mechanism locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. Page 2220 The mark on the sprocket for roller chain -4- must be aligned with notches -C- or -D- on the thrust washer. Page 1614 Compression Check: Testing and Inspection Compression pressure, checking Special tools, equipment, test and inspection devices; required accessories 3122 B Spark plug removal tool - T10029 Spark plug connector tool - VAG 1331 Torque wrench (5-50 Nm) - VAG 1763 Compression tester Test condition - Engine oil temperature must be at least 30°C. - Battery voltage must be at least 11.5 V. Test procedure - Disconnect connector from heating resistor (N79) and remove intake hose between upper half of air filter and throttle control unit (J338) together with crankcase purge valve. - Use assembly tool T10029 to remove spark plug connector and ignition lines. - Remove engine cover. - Remove spark plugs with spark plug tool 3122 B. Page 3580 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 3594 Oxygen Sensor: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Recall - Hazard Switch Replacement Technical Service Bulletin # RECALLVX Date: 050301 Recall - Hazard Switch Replacement Code: VX March 2005 Subject: 2000-2001 Model Year Golf/GTI (German built), 2000-2002 Golf/GTI (Brazilian Built) and 2000-2002 Jetta Vehicles Replace Emergency Light Switch (Hazard Switch) This is to inform you of the initiation of a safety recall involving some 2000-2002 model year Jetta, Golf and GTI vehicles. Problem Description Volkswagen has found that, in some cases the hazard switch and flasher system function in affected vehicles may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays (which occurs due to substantially increased electrical current load from higher-wattage turn signal bulbs). This may result in intermittent or inoperative turn signal and hazard flasher function. Remedial Action Replace the emergency light switch. Vehicle Identification Number Ranges Limitation of Sale or Lease of Certain Vehicles The National Traffic and Motor Vehicle Safety Act of 1966, as amended, mandates that dealers correct, prior to delively for the sale or lease, any vehicle which fails to comply with an applicable Federal Motor Vehicle Safety Standard or which contains a defect relating to motor vehicle safety. It is therefore Imperative that any vehicle in your new or used car Inventory and affected by this recall is corrected prior to delivery for sale or lease. Owner Notification Mailing Volkswagen Will notify all known owners of affected vehicles directly by first-class mail on or about March 31. 2005. A sample copy of the owner letter is shown for your information Vehicle Allocation A computer list containing the VINs including the owner names and addresses of vehicles that, according to our records, are located within your area of responsibility (AOR) and require this action to be performed will be provided under separate cover. Note: The above listing includes names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations Page 187 Part 2 Page 5150 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 6041 Power Distribution Relay: Locations Power Supply (Terminal 30, B+) Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1267 - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -3-, and -4- to input display group number 34 (034) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 34 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by the Engine Control Module (ECM). - Check specified values in display fields 1-4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 2850 - Check wires between test box and 4-pin connector (to control module) for open circuit according to wiring diagram. Terminal 3 + socket 68 Terminal 4 + socket 69 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1559 Adjusting toe, Refer to Alignment, Service and Repair, toe 5. Check which suspension component is installed in the vehicle. This information is found on the vehicle data sticker,Refer to Alignment Testing and Inspection, Vehicle data Sticker Lighting - Brake Light Switch Installation Precaution Brake Light Switch: All Technical Service Bulletins Lighting - Brake Light Switch Installation Precaution Group: 46 Number: 04-01 Date: Feb. 17, 2004 Subject: New Style Brake Light Switch Requires Care During Installation to Prevent Damage to Switch Model(s): Golf, Jetta 1999 --> 2004 New Beetle 1998 --> 2004 Supersedes T.B. Group 46 Number 03-01 dated Nov. 7, 2003 Revised brake switch Part No: 1J0 945 511D may be damaged during installation if not properly installed. The revised switch Part No: 1J0 945 511D: ^ Currently supersedes brake switch Part Nos: 1J0 945 511A and 1J0 945 511B and 1J0 945 511C for the models listed (does not include Eurovan). ^ Part Nos. 1J0 945 511B , 511C, and 511D may be installed only once, if switch is removed, it must be replaced with a new switch. ^ Can only be tested in the installed position. ^ Contains internal switch(es) which can be damaged if not correctly installed and adjusted properly. CAUTION! DO NOT depress plunger prior to installation. Service If brake switch requires replacement: - Remove cover below instrument panel. - Disconnect connector from brake switch. - Identify Part No. suffix (A, B, C or D) of switch installed. - Remove switch using the appropriate procedure for the Part No. suffix. 1. Brake switch, Part No: 1J0 945 511A, removing: Locations Radiator Cooling Fan Control Module: Locations J293 Coolant Fan Control (FC) control module - engine compartment, lower left, below front longmember With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Page 2238 - Set and check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear -13- must be aligned with the bearing parting line (TDC cyl. 1). - Install bolt without collar for sliding rail -2- and tighten to 10 Nm. - Install sliding rail -2- with roller chain -1- and both sprockets -3- and -4- (note direction of travel of roller chain. The mark on the sprocket for roller chain -4- must be aligned with notches -C- or -Don the thrust washer. - Release stop teeth in chain tensioner with a small screwdriver -A-. - Press tension bar against chain tensioner and tighten chain tensioner to 10 Nm. Page 375 - Press -> button until "Select function" appears in display. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select "Adaptation" function 10. Indicated on display: Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display: Adaptation Enter channel number XX - Press buttons -0- and -3- to select adaptation "channel 03". - Press -Q- button to confirm input. Indicated on display: Channel 03 Adaptation 100 -> <-1 3-> - Press -> button to continue. NOTE: Correction of fuel consumption display is only possible via direct input. Indicated on display: Channel 03 Adaptation 100 Enter adaptation value XXXXX - Input desired correction value using scan tool button pad, filling initial positions with "0". Example: Desired input value: 90% = button pad entry: 00090 Indicated on display: Channel 03 Adaptation 100 Q Enter adaptation value 00090 - Press -Q- button to confirm input. Indicated on display: Channel 03 Adaptation 90 Q <-1 3-> - Press -Q- button to confirm input. Indicated on display: Channel 03 Adaptation 90 Q Store changed value? - Press -Q- button to confirm input. Indicated on display: Page 4485 All functions, which could previously be performed with V.A.G 1551/1552, can also be performed with the new tester VAS 5051 in the vehicle self-diagnosis operating mode: - VAS 5051 Vehicle diagnosis, testing and information system ATF Level, Checking Conditions for performing check Transmission not in emergency running mode, ATF temperature not above approx. 30°C - Vehicle level - Selector lever at "P" - Remove sound insulation tray. - Remove sound insulation from left longitudinal member. - Secure reservoir of ATF filling system V.A.G 1924 to vehicle. - If using tester VAS 5051, connect diagnosis cable VAS 5051/1 or VAS 5051/3 with ignition switched off to Data Link Connector (DLC). Page 6446 1. Axle shaft ^ For special model "Golf GTI 132 kW" ^ Pulling axle shaft out from wheel hub and pressing in 2. Axle shaft ^ Pulling axle shaft out from wheel hub and pressing in 3. Speed sensor 4. Hex socket head bolt, 10 Nm (89 in lb) 5. Suspension strut 6. Hex bolt ^ Always replace ^ The point on the hex bolt must point in normal direction of travel 7. Tie rod end 8. Self-locking nut ^ 60 Nm (44.2 ft lb) plus an additional 90° - 1/4 turn ^ Never less then 90°! ^ Turning angle tolerance 90 to 120° ^ Always replace 9. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 10. Wheel bearing housing For vehicles: ^ With gasoline engines up to and including 92 kW(123 Hp) ^ With SDI/TDI engine Page 3789 Indicated on display (1-4 " display fields) Press brake pedal and hold. Note: The engine control unit will increase the engine speed. - Check catalytic converter conversion (amplitude ratio) in field 3: Specification: 0.50 maximum - Let engine run at higher speed until "Cat B1 OK" is displayed in field 4. If the diagnosis is started by the engine control unit, field 4 will jump from "Test OFF" to "Test ON." Note: Diagnosis of the catalytic converter lasts about 100 seconds. Page 4851 1. Flywheel - Ensure centering pins are a tight fit - Contact surface for clutch lining must be free of grooves, oil and grease - Removing and installing. Refer to Flywheel, M/T. 2. Clutch plate - Diameter. Refer to Specifications - Installation position on two-part flywheel: shorter hub end (arrow) faces pressure plate - Installation position with single piece flywheel: spring cage faces pressure plate - Centering refer to Fig. 1 - Lightly grease splines Note: Clean input shaft splines and on used clutch plates, the hub splines. Remove corrosion and apply only a very thin coating of grease Part No: G 000100 to the input shaft splines. Then move clutch plate back and forth on input shaft until hub moves freely. Excess grease must be removed. 3. Pressure plate - Removing and installing refer to Fig. 1 - Check ends of diaphragm spring refer to Fig. 2 Note: Pressure orates are protected against corrosion and greased. Only the contact surface may be cleaned, otherwise the service life of the clutch will be considerably reduced. 4. Bolt - Allocate using parts catalog - On two-part flywheel: 13 Nm - On single piece flywheel: 20 Nm - Loosen and tighten gradually and diagonally Page 3659 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Exhaust System - Heat Shield Replacement Guidelines Heat Shield: Technical Service Bulletins Exhaust System - Heat Shield Replacement Guidelines 26 08 02 Aug. 28, 2008 2015831 Supersedes T.B. Group 26 Number 07 - 07 Dated October 2, 2007 Due to removal of Routan applicability. Vehicle Information Condition Exhaust Heat Shield, Replacement Guidelines Underbody heat shields are important for proper vehicle performance. Heat Shields are to be inspected after completion of any type of repair to the underbody (exhaust system, transmission, etc.), and if damaged, replaced Technical Background Damaged heat shields may exhibit the following symptoms: ^ Bent / Moved out of tolerance heat shield material ^ Lack of sufficient clearance ^ Torn / Damaged heat shield material ^ Contaminated (fluid saturation) heat shield material ^ Peeling / Separating heat shield material resulting from damage Production Solution No production change required. Page 3833 Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure, Checking Fuel Pressure Regulator And Residual Pressure, Checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). The specified value for this test is dependent on the working pressure of the Fuel Pump (FP). This is about 3.0 bar positive pressure Recommended special tools and equipment - V.A.G 1318 pressure gauge - VAG1318/10 adapter - VAG1318/11 adapter - VAG1318/16 hose adapter - VAS5024 assembly tool for spring-type clamps Test requirements - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Delivery quantity of Fuel Pump (FP) OK, Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Vehicles with engine code AFP Page 5329 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 2979 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Page 3241 - Switch ignition off. NOTE: If the basic setting of the control module is interrupted, the cause could be one of the following: - Throttle valve cannot reach the mechanical stop because of contamination (e.g. oil deposits or an incorrectly adjusted accelerator pedal cable). - Battery voltage too low. - Throttle valve control module or wiring is faulty. Refer to "Throttle Valve Control Module, Checking", See: Electronic Throttle Control Module/Testing and Inspection After an interruption the fault "17973" is stored in DTC memory. When the ignition is switched on again, the basic setting is automatically performed again. - End basic setting by pressing -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 79 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -4-. ^ Location: Above rear glass under headliner. Antennas All models use four antennas. ^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-. - Jetta / Golf / Passat (non W8) - Antenna system ^ All models use External amplified antenna mast -1-. Page 3863 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 642 Test Sep 7 - 9 Page 4818 Part 2 Page 1305 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 3657 Part 2 Brakes - Vibration/Pulsation Upon Application Brake Rotor/Disc: Customer Interest Brakes - Vibration/Pulsation Upon Application 46 10 05 October 25, 2010 2015173 Supersedes T.B. V461002 dated February 17, 2010 to add additional models and 2011 model year applicability. Vehicle Information Condition Brake Disc, Pulsation When applying brakes at highway speeds the following symptoms may occur: Brake pedal may pulsate Vibration may be felt in vehicle body Steering wheel may shake Technical Background For brake vibration / pulsation concerns, brake disc machining is now allowed between 6 months / 6000 miles and 12 months /12,000 miles of the warranty in service date. Note Production Solution No production change required. Service Note: Procedure: Page 1595 8 - 6 Nm (53 in. lb) 9 - Filter element 10 - Air cleaner lower section 11 - Air duct 12 - 10 Nm (ft lb) 13 - O-ring Always replace if damaged 14 - Intake hose Ensure seated tightly - Press together at front to release - To Secondary Air Injection (AIR) pump motor -V101-: 15 - Connecting hose For crankcase breather - From breather housing on cylinder head cover 16 - Connecting hose Note installation position - From T-piece connection on intake manifold upper section /Evaporative Emissions (EVAP) canister purge regulator valve -N8017 - Positive Crankcase Ventilation (PVC) heating element -N79- For crankcase breather 18 - To throttle valve control module -J338-* Page 4236 Part 1 Page 5268 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 5181 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1089 Special Tools and Equipment Work Sequence Section A - Emergency Li9ht Switch Replacement ^ Switch off all electrical consumers and remove key from ignition switch. ^ Emergency light switch -3- is the center switch in the instrument panel. ^ To remove emergency light switch, the ESP or ASR switch -2- must be removed, and to remove the ESP or ASR switch, the seat heater switch - 1 - must be removed. ^ If an ESP or ASR switch -2- is located next to the emergency light switch, go to Section B; otherwise, continue. Page 2309 - Disconnect 5-pin connector from ignition coil (N152). - Disconnect fuse no. 32 from fuse block. Note: By removing fuse 32, the voltage feed to the injector valves is interrupted. - Completely depress accelerator pedal for wide open throttle. - Check compression pressure with compression pressure tester VAG 1763. - Crank engine until tester no longer shows an increase in pressure. Compression pressure readings: New: 10 - 13 bar Max. wear: 7.5 bar Permissible variation between all cylinders: 3 bar Page 4593 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 4401 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Customer Safety Information A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools A/T - Pan Gasket Appears to be Leaking Fluid Pan: Customer Interest A/T - Pan Gasket Appears to be Leaking Group: 37 Number: 01-01 Date: Mar. 5, 2001 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Supersedes T.B. Group Number 37 Number 00-02 to reflect new part number Condition Transmission appears to be leaking around ATF pan gasket. In most cases the leak is NOT caused by the ATF pan gasket, but by the main line pressure plug (arrow). ATF fluid flows down from main line pressure plug to pan seal, giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace with Part No: N 904 142 01 (plug with seal) - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases, a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. Page 2308 Compression Check: Testing and Inspection Compression pressure, checking Special tools, equipment, test and inspection devices; required accessories 3122 B Spark plug removal tool - T10029 Spark plug connector tool - VAG 1331 Torque wrench (5-50 Nm) - VAG 1763 Compression tester Test condition - Engine oil temperature must be at least 30°C. - Battery voltage must be at least 11.5 V. Test procedure - Disconnect connector from heating resistor (N79) and remove intake hose between upper half of air filter and throttle control unit (J338) together with crankcase purge valve. - Use assembly tool T10029 to remove spark plug connector and ignition lines. - Remove engine cover. - Remove spark plugs with spark plug tool 3122 B. Page 4724 - Remove selector lever cable -1- from retainer-arrow- on engine. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Pry selector lever cable -3- off selector lever -2- with a screwdriver. - Pull out selector lever cable locking plate -1- on mounting bracket downward. - Pull selector lever cable carefully out of mounting bracket. - Remove selector mechanism completely out of tunnel. Installing - Check the protective sleeve for damage; the protective sleeve can only be changed together with the selector lever cable. - Check that the protective sleeve is correctly tiffed. Do not install protective sleeve twisted. - Do not bend or kink the selector lever cable. - Selector lever and lever/selector shaft are in "P" position, the front wheels are blocked. Page 1383 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 1238 L4 Engine W/1 Exhaust Banks & 1 Catalysts Service and Repair Door Switch: Service and Repair Door Contact Switches, Removing And Installing Door contact switches are integrated into the individual door lock mechanisms and cannot be replaced separately. In case of door contact switch malfunction, replace complete door lock mechanism. Page 387 Fog/Driving Lamp Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 3442 Page 4220 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 5464 ^ Disconnect wheel speed sensor wiring connector -1-. ^ Remove bolt -2- from wheel bearing housing. ^ Remove wheel speed sensor from wheel bearing housing. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat sensor with lubricant G 000 650. ^ Insert speed sensor into mounting hole in wheel bearing housing and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor wiring connector. ^ Turn wheels fully to left and right lock and check clearance of speed sensor wiring. ABS wheel speed sensor rotor for front axle, checking ^ Raise vehicle. ^ Remove wheel. ^ Rotate brake disc and check whether wheel speed sensor rotor is damaged or dirty. ^ If rotor is damaged, remove wheel hub with rotor and replace. ^ Raise vehicle. ^ Remove wheel. ^ Turn wheel hub and measure distance between rotor and speed sensor, -dimension a, all around. Dimension a = 0.3 mm (0.0118 in.) ^ If the rotor is not true, remove wheel hub with rotor and replace. Page 3563 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor -G70-, item 4. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Description and Operation Coolant Temperature Sensor / Switch HVAC: Description and Operation A/C cut-out thermal switch -F163- (Item # 9 in image) - Switches off A/C clutch -N25- at excessively high coolant temperatures. - Off at 119 °C (246 °F) - On at 112 °C (234 °F). Page 4343 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Emissions - Possible MIL ON/Cat Converter DTC's Set Catalytic Converter: Customer Interest Emissions - Possible MIL ON/Cat Converter DTC's Set 26 07 06 Sept. 13, 2007 2010271 Supersedes T.B. Group 26 number 07 01 dated Feb. 9, 2007 due to the removal of 2001-2003 2.0L (AVH, AZG, BDC) engines. Vehicle Information Condition Catalytic Converter, Replacement Guidelines Catalyst efficiency faults stored in memory (See DTC table). Technical Background Guidelines for catalytic converter replacement Page 268 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 3145 Part 1 Page 4135 - Tighten both bolts -arrows B- to 25 Nm. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Reconnect Ground strap to battery. - Check selector mechanism. - Enter radio code. Specifications Clutch Fluid: Specifications Hydraulic clutch Brake fluid For further specifications refer to Brakes and Traction Control. Page 6181 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 907 High Pressure Sensor / Switch: Testing and Inspection High Pressure Sensor - G65 - High Pressure Sensor -G65-, Checking NOTE: - The presence of -G65- is engine dependant. Where -G65- is not used, A/C pressure switch -F129- is used instead. - Where -G65- is used, it's wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of either -065- or -F129- and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Special tools and equipment required - VAG 1767 Ignition tester - VAG 1594/A (or C) Connector test set - VAG 1598 A Test box - Applicable wiring diagram - In cases where refrigerant system may need to be recharged, use kent Moore ACR4 (or equivalent) (VAG 1885 illustrated). - Where necessary: VAG 1551/1552 Scan Tool - Optional: VAS 5051 Vehicle Diagnostic Testing and Information System Capacity Specifications Final Drive Fluid: Capacity Specifications Final Drive Capacities 01M Transmission Initial Filling .......................................................................................................................................... ............................................ 0.75 liter (0.80 quarts) Page 1713 Note: Always replace cap. The cap secures the sealing plug. Ending output of V.A.G 1551 Indicated on display Press (arrow) key. Indicated on display Press keys 0 and 6 (The function "End output" is selected with 06). Indicated on display Confirm entry with Q key. Indicated on display - Lower vehicle. - Switch ignition off. - Disconnect connection to V.A.G 1551 Scan Tool. Page 2966 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Locations Headlamp Wiper Relay: Locations Relay/Fuse Arrangements On The Relay Panel Relay Arrangements On The Thirteenfold Auxiliary Relay Panel, Above Relay Panel Page 2318 Water Pump: Service and Repair Coolant pump, removing and installing (with engine installed) Special tools and equipment 10-222A Engine support bracket with legs 10222A/1 T10007 Refractometer VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 Nm) VAG 1332 Torque wrench (40...200 Nm) VAG 1590 Coolant pump wrench VAS 5024 Assembly tool for spring-type clips VAS 5085 Ladder Page 6355 Steering Wheel: Scan Tool Testing and Procedures Connecting VAG 1551 VAG 1551 Scan Tool (ST), Connecting, Selecting Functions And Checking Control Module Versions Prerequisites: - All fuses OK according to wiring diagram. - Battery (B+) voltage at least 9 Volts. NOTE: - VAG 1552 Scan Tool (ST) may be used instead of the VAG 1551 Scan Tool (ST), however a print-out is not possible. - The following procedure and display references pertain only to VAG 1551 Scan Tool (ST). Connecting With ignition switched off, connect VAG 1551 Scan Tool (ST) with adapter cable VAG 1551/3 to the Data Link Connector (DLC) as follows: - Remove cover for Data Link Connector (DLC) under left instrument panel. - Connect Scan Tool using adapter cable VAG 1551/3. Indicated on display: On Board Diagnostic (OBD) HELP 1 - Rapid data transfer* 2 - Flash code output* *Is displayed alternately Functions, selecting NOTE: - If the display remains blank check Scan Tool (ST) voltage supply according to wiring diagram. - Additional operating instructions can be called up by pressing the HELP button. - The -> button is used to advance through the program sequence. - In operating mode 7 "Rapid data transfer," function 00 "Automatic test sequence" can be carried out. The DTC memory of all control modules with OBD capability are checked automatically. - Switch on ignition. - Switch on printer with the Print button (indicator lamp in button lights up). - Press button 1 for "Rapid data transfer" mode. Indicated on display: Rapid data transfer HELP Input address word XX Page 1590 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the idle speed is not obtained: - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. See: Powertrain Management/Computers and Control Systems/Engine Control Module/Testing and Inspection - Carry out road test. Observe the valid safety precautions when carrying out a road test. See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Technician Safety Information - Check DTC memory again. - Repeat idling check. If the specified values are not obtained again: - Check throttle valve control module. - Check intake air system for unmetered air. - Check operating condition of engine. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Operating Conditions, Checking - Check signals from/to air conditioner. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/A/C Compressor Signal, Checking Page 2226 - Install cover piece, insert all mounting bolts and turn in opposite direction slightly. CAUTION: Do not damage Cylinder Head Gasket, when installing timing covers. - Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. Page 2202 3428 - New TDI Cam Lock Bar Specifications Spark Plug: Specifications Spark Plugs AFP VW Part Number ................................................................................................................................. ................................................. 101 000 035 AH Manufacturer Designation (NGK) ............................................................................................................................................................ BKR 5 EKUP Spark Plug Gap ............................................................................................................. ....................................................................................... 0.7 mm Tightening Torque .......................... ...................................................................................................................................................... 25Nm (18 ft. lb.) Page 3990 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 6111 S179 - Fuse -7- (30) in fuse bracket/battery S180 - Fuse -8- (30) In Fuse Bracket/Battery S180 - Fuse -8- (30) in fuse bracket/battery Page 2242 - Install cylinder head. - Push sliding rail onto bearing bolt. Insert short mounting bolt with "D6" locking compound and tighten both bolts to 20 Nm. - Mount camshaft sprocket with camshaft roller chain to camshaft for cylinder bank 1, 3 and 5 (long camshaft) and turn in opposite direction by hand. - Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4 and 6 and turn in opposite direction by hand. Note: Coat contact surfaces of the bolt heads with oil when installing. - Remove camshaft guide 3268. - Tighten mounting bolts for camshaft sprockets to 100 Nm. Note: Hold camshaft -arrow- only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02. - Coat O-ring for oil passage seal and insert in cover piece. - Install cover piece, insert all mounting bolts and turn in opposite direction slightly. - Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. - Install chain tensioner for camshaft roller chain and tighten to 40 Nm. Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip. - Rotate crankshaft twice in engine travel direction and check timing. Marking roller chains - Mark roller chains before removal (e.g., put an arrow in direction of travel with paint). Note: Do not mark the chain with a center punch, chisel, etc. Page 3945 - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose -1- and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Continuation for all vehicles - Start engine and let run at idle. - Measure fuel pressure. Specified value: about 2.5 bar positive pressure Vehicles with engine code AFP - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Vehicles with engine code BDF - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Continuation for all vehicles Page 322 ABS Control Module W/Electronic Differential Lock And Anti-slip Control (ASC) From August 2000 Control Modules - Connector Pin-out Page 6078 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 6357 NOTE: - Output Diagnostic Test Mode cannot be initiated, or will be interrupted if engine is running or vehicle is moving. - Use the -C- button to exit the test sequence at any time. - Connect VAG 1551 Scan Tool (ST), input address word 56 "Radio" and then press -> button, until "Select function XX" is shown in display. Indicated on display (select function): Rapid data transfer HELP Select function XX - Press buttons -0- and -3- to select "Output Diagnostic Test Mode" function 03. Indicated on display Rapid data transfer Q 03 - Output Diagnostic Test Mode - Press -Q- button to confirm input. Indicated on display: Output Diagnostic Test Mode -> Segment test "AAAABBBBCCCCDDDD" will appear in the instrument cluster display. - Switch on radio system, tune in radio program and set to middle volume. - Press -> button. Indicated on display: Output Diagnostic Test Mode -> Radio louder The volume increases. - Press -> button. Indicated on display: Output Diagnostic Test Mode -> Radio quieter The volume decreases. - Press -> button. Indicated on display: Output Diagnostic Test Mode -> Station search up-band Station search for the next radio station up-band which will appear in radio display (and in display in instrument cluster where applicable). - Press -> button. Indicated on display: Output Diagnostic Test Mode -> Station search down-band Station search for next radio station down-band which will appear in radio display and (and in display in instrument cluster where applicable). - Press -> button. Page 1090 ^ If there is no ESP or ASR switch and only a blank cover -2-, apply adhesive tape to instrument panel under cover, use a flat screw driver -A- to remove cover. ^ Insert assembly tool T10034 into opening, release clip holding emergency light switch -3- and pull it out of instrument panel. ^ Disconnect connector from emergency light switch. ^ On new emergency light switch (1J0 953 235 J 01C) reconnect connector and install switch into instrument panel. ^ Reinstall blank cover and remove adhesive tape. ^ Check turn signal and emergency light switch for correct operation. ^ Check all turn signal and emergency light switch bulbs for illumination and replace as required. ^ Destroy and properly dispose of removed part(s). Section B - Emergency Light Switch Replacement on Vehicles with ESP or ASR Page 2108 Ch-Fu Page 3189 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 6348 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Page 2262 Variable Valve Timing Actuator: Testing and Inspection With Generic Scan Tool Valves For Camshaft Adjustment (Vehicles With Engine Code BDF), Checking Function The camshaft adjustment is load-and RPM dependent. The electrical valves for camshaft adjustment switch oil pressure onto camshaft adjusters (mechanical adjustment mechanisms), which then adjust the camshafts. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of the Valve -1- for camshaft adjustment -N205-and Camshaft Adjustment Valve 1 (exhaust) -N318- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P-or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Disconnect 2-pin harness connector to the respective valve for camshaft adjustment: 1 - Valve -1- for camshaft adjustment -N2052 - Camshaft Adjustment Valve 1 (exhaust) -N318NOTE: Before disconnecting harness connectors, mark allocation to component. Page 3127 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 2905 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 4466 Drain Plug: Specifications 5 Speed 09A Transmission 5 Speed 09A Transmission Drain Plug............................................................................................................................................. ................................................................... 45 Nm Page 3712 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 2757 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Alloy Wheels - Cleaning Procedure Wheels: Technical Service Bulletins Alloy Wheels - Cleaning Procedure Group: 44 Number: 01-05 Date: Aug. 21, 2001 Subject: Alloy Wheels, Cleaning Model(s): All with Alloy Wheels Supersedes T.B. Group 44 number 01-04 dated Aug. 16, 2001 due to Part No. correction. Condition Alloy wheels have a build-up of road dirt or brake dust. Service CAUTION! Some aggressive, harsh wheel cleaners can damage the finish on alloy wheels. Always read and follow manufacturer Cautions and Warnings regarding use of product. - Alloy wheels can be cleaned without damaging the wheel finish by using Alloy Wheel Cleaner Part No: ZVW 902 106. - Follow detailed instructions on wheel cleaner container. Note: Please in form your customers regarding the recommended cleaning of alloy wheels. Cleaning alloy wheels is NOT covered under the New Vehicle Warranty Page 4919 - Install boot clamp. - Tighten small hose clamp with pliers VAG1275. NOTE: To prevent triple rotor joint from being pushed back unintentionally when installing axle shaft, secure triple rotor joint with adhesive tape. - Remove adhesive tape just before bolting to axle flange. Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 5820 2. Check and/or charge battery based on applicable Technical Bulletin. 3. If INC-940 test fails battery, replace battery before continuing. Step 2: Verify Sleep State Current 1. Connect 50 amp current clamp to VAS 5051A/B. 2. Calibrate the current clamp. 3. Connect current clamp to negative battery cable with arrow pointing away from battery. 4. Close all doors, trunk, or hood latch so vehicle control units detect all doors closed. 5. Arm vehicle anti-theft system with remote. 6. Observe sleep state current draw after vehicle is left untouched for TWO HOURS. 7. If after two hours the vehicle exceeds maximum sleep state current draw, proceed to Step 3: Consuming Circuit Isolation. If vehicle does not exceed maximum sleep state current draw, perform a long term (overnight) measurement test. Record the long term measurement using MIN/MAX setting of scan tool. ^ Excessive current = Measured current > nominal sleep current Step 3: Consuming Circuit Isolation Starting at interior fuse boxes, perform the following tasks: Page 4737 - Guide selector lever cable -3- with a new seal into selector lever housing. - Press selector lever cable onto selector lever -2-. - Install new selector lever cable circlip -1- onto selector lever housing. Installation position: The angled end of the circlip must face to the inside of the selector lever housing. Move selector lever from "P" to "1". Selector lever mechanism and selector lever cable must move freely. If necessary replace selector lever cable or service selector lever mechanism. - Shift selector lever into "P" position. - Loosen bolt -2- at front ball socket -1- of selector lever cable. - Place selector lever cable in support bracket/transmission and push onto lever/selector shaft. - Install new circlip -3- to selector lever cable at support bracket/transmission. Page 565 Engine Control Module: Service and Repair Replacement ECM, Adaptation (Function 10) Replacement Engine Control Module (ECM), Adaptation (function 10) NOTE: - The engine control module is adapted to the immobilizer control module in the instrument cluster. When changing a component it must be readapted. - If an authorized ignition key is not available but the secret number is, new ignition keys must be manufactured and adapted. - The adapting can be interrupted with the "C" button of VAG 1551 Requirements Authorized ignition key available. - Insert old (authorized) key in ignition lock. - Connect VAG 1551, select operating mode 1, "Rapid data transfer". Switch ignition on and enter address word 17, "Instrument cluster". After control module identification has been displayed: Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select function 10, "Adaptation". Indicated on display Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display Adaptation Enter channel number XX - Press button -0- twice to select "Channel O". - Press -Q- button to confirm input. Indicated on display Adaptation Q Erase learned value? - Confirm entry with -Q- button. Indicated on display Adaptation -> Learned values are erased - Press -> button. Indicated on display Rapid data transfer HELP Page 1709 - Always replace seal -arrow- on ATF inspection plug. ATF Level, Checking Test conditions: Transmission not in emergency running mode, ATF temperature not above approx. 30°C - Vehicle level - Selector lever in "P", parking brake applied - Secure reservoir of ATF filling system V.A.G 1924 to vehicle. Connecting vehicle diagnosis, testing and information system VAS 5051 All functions which could previously be performed with V.A.G 1551 can also be performed with the new tester VAS 5051 in the operating mode "Vehicle self-diagnosis": Page 5110 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Specifications Connecting Rod Bearing: Specifications Connecting rod Axial clearance New 0.05 - 0.31 mm Max. wear 0.40 mm Radial clearance New 0.02 - 0.07 mm Max. Wear 0.10 mm Bolts 30 Nm plus 1/4 turn Locations Trunk/Liftgate Sensor/Switch (For Alarm): Locations F124 - Trunk lock alarm/central locking switch Page 238 Part 2 Page 5557 ^ Remove seal using wedge 3409. Note: When removing the piston seal make sure that the cylinder bore is not damaged. Installing ^ Thinly coat piston and piston seal with assembly lubricant G 052 150 A2 before inserting. ^ Place protective seal with outer sealing lip on piston. ^ Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409. Page 3991 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Locations Acceleration/Deceleration Sensor: Locations G419 - ESP-Sensor Unit (vehicles with ESP) Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 4619 - Remove sound insulation tray-arrows-. - Remove right sound insulation. - Turn steering to right onto full lock stop. - Disconnect drive shaft from flanged shaft. - Raise right drive shaft and secure. - Remove flange shaft securing bolts by threading two bolts into flange and counterhold flange shaft using a lever. - Place drip tray under transmission. - Remove flanged shaft with spring. - Pull flange shaft oil seal out using VW 771 and VW 771/37. Installing right-hand flange shaft seal - Drive in new seal until thrust piece contacts stop. Ensure that seal remains straight when driving. - Insert flange shaft. - Apply sealant D 176 404 A2 to head of countersunk bolt. - Secure flange shaft with countersunk bolt. - Bolt right-hand drive shaft to flange shaft. - Check and top up ATF level with transmission installed. Page 2113 Sh-SW Page 908 Test conditions - Workshop temperature: 20-30 °C (68-86 °F) - Engine at Workshop temperature. Making connections NOTE: - The following test procedure is only possible on vehicles where the - G65- square wave signal to the coolant fan control module -J2293- is also transmitted to the Motronic Engine Control Module (ECM). Con firm -G65- circuit using wiring diagram. - On vehicles where -G65- is NOT connected to the ECM, connect green clip from VAG 1767 directly to -G65- pin 2 using appropriate VAG 1594 adapter cable -7-. Proceed directly to checking Disconnect engine harness electrical connector from Engine Control Module (ECM) -3-. - Locate correct test box VAG 1 598A -4- and adapter according to pin assignments of ECM -3and connect test box to engine wiring connector/harness -2-. - Connect black clip from VAG 1767 to Ground (GND) -5-. - Determine applicable - G65- signal input pin assignment to ECM using wiring diagram. Example: T121/61 NOTE: - As -G65- function primarily controls coolant fan and A/C clutch operation, the engine wiring diagrams may indicate the - G65- signal connection as being "Coolant fan control module connection". - ECM terminal number assignments correspond with those on test box VAG 1598A. Connect green clip from VAG 1767 to the corresponding numbered position on test box VAG 1598A connected to -G65- pin -2- using appropriate VAG 1594 adapter cable - 7-. Example: 61 Page 4357 1. Supporting ring - 4-piece, unclip from inner plate carrier - Inserting see Fig. 2 2. Inner plate carrier - Inserting see Fig. 4 - Assembling see Fig. 2 3. Circlip - Different thicknesses - Mark after removing and insert in same position 4. Thrust plate - Smooth side faces inner plate - Insert together with inner plate carrier see Fig. 2 5. Inner plate - Installing see Fig. 2 6. Outer plate - Installing see Fig. 2 - Always 1.5 mm thick 7. Outer plate - Always 2 mm thick - Installing see Fig. 2 8. Corrugated washer 9. Circlip - Removing and installing see Fig. 1 10. Piston cap - Sealing lips are vulcanized to cap Page 3913 17 - Wiring Harness. - With harness connectors for fuel injectors. 18 - 5-Pin Harness Connector. Black. - For Mass Air Flow (MAF) sensor - G70 - with Intake Air Temperature (IAT) sensor - G42 -. - Sensor and harness connector contacts are gold plated. 19 - 6 Nm ( 53 in. lb ). 20 - Retaining Clip. 21 - O-ring. Replace if damaged. 22 - Thermostat Housing. Page 4495 Note: Always replace cap. The cap secures the sealing plug. Ending output of V.A.G 1551 Indicated on display Press (arrow) key. Indicated on display Press keys 0 and 6 (The function "End output" is selected with 06). Indicated on display Confirm entry with Q key. Indicated on display - Lower vehicle. - Switch ignition off. - Disconnect connection to V.A.G 1551 Scan Tool. Page 986 - Prior to Installation, pull out brake switch plunger (black arrow) to full extension. - Apply a light coat of lubricant Part No. G 052 142 A2 to end of plunger (black arrow). Lubricant is considered shop supply. - Keep brake pedal in the up position (IMPORTANT! hold pedal up if necessary while installing switch). - Push switch in and seat fully into opening (pressing plunger against pedal to adjust). - Once seated, secure switch by turning it to the right approx. 45° (must be turned fully to it's stop! see magnified views below). ^ This action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate as well as locks in plunger (arrow) adjustment. Once installed, inspect internal stop pin of switch (inset) for correct positioning (see examples below). CAUTION! When installing, the switch must be rotated until it is fully locked and electrical connector is in the horizontal position. Page 592 Starter Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 4813 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1358 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Powertrain Management/Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity 2.8L 174hp AFP Capacity ............................................................................................................................................... ............................................... 5.5 liters (5.8 quarts) Compiled From Every Wiring Section 1998-2004 Starter Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1542 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6110 S177 - Fuse -5- (30) in fuse bracket/battery S178 - Fuse -6- (30) In Fuse Bracket/Battery S178 - Fuse -6- (30) in fuse bracket/battery S179 - Fuse -7- (30) In Fuse Bracket/Battery Page 1175 - Connect multimeter between terminal 2 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 4-pin connector terminal 2 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with 2-pin clutch vacuum vent valve switch - Check wire between test box and 2-pin connector for open circuit according to wiring diagram. Terminal 2 + socket 39 Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch - Check wire between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 39 Page 157 Page 155 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Service and Repair Headlamp Switch: Service and Repair Light Switch -E1-, Removing And Installing Removing - Turn rotary switch to "0" position. - Press rotary part inward -1- and turn slightly to right -2-. - Hold rotary part in this position and pull light switch out from instrument panel -3-. - Disconnect electrical connection. Installing: - Connect electrical connector. - Hold light switch and press rotary part inward -1- and turn slightly to right -2-. - Hold rotary part in this position and insert light switch into instrument panel -3-. - Turn rotary part to position "0", release and engage switch Page 5357 Page 3225 Engine Control Module: Locations Engine Control Module Engine Control Module location The control module is located in plenum chamber. Page 4930 11. Ball joint ^ Checking; Refer to Ball joint; Testing and Inspection 12. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 13. Shield plate 14. Hex bolt, 10 Nm (89 in lb) 15. Hex bolt ^ For special model "Golf GTI 132 kW" ^ Always replace 16. Self-locking 12-point nut ^ Always replace 17. Phillips screw, 4 Nm (35 in lb) 18. Ventilated brake disc 19. Wheel hub with speed sensor rotor ^ Rotor is welded to wheel hub 20. Circlip ^ Make sure seated correctly 21. Wheel bearing ^ Pressing wheel bearing out of wheel bearing housing ^ Replace, as it is destroyed during pressing out ^ Pressing wheel bearing into wheel bearing housing 22. Wheel bearing housing For vehicles: ^ With gasoline engines from 110 kW (147.5 Hp) Pressing wheel hub out of wheel bearing housing Page 5322 A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection A/C Pressure Switch F129 A/C Pressure Switch, Electrical Checks Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10.8mm x 1.8mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan V7 (via the coolant fan control module J293 ) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). A/C Pressure Switch, Functional Checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch N25 engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), F129 switches A/C clutch off. - Check cooling fan function. When system pressure increases, F129 causes coolant fan V7 to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condensor is blocked), F129 switches A/C clutch off. Page 2177 Valve Guide Seal: Tools and Equipment Valve Seal Installer AST tool# 3365 This tool is used to install valve stem seals on VW 2.8 liter V-6 5 valve per cylinder engines, 1.8 liter turbo 5 valve per cylinder engines, 4.0 liter W-8 4 valve per cylinder engines, Audi 4.2 liter V-8 5 valve per cylinder engines, 1.8 liter turbo 5 valve per cylinder engines and 3.0 liter V-6 5 valve per cylinder engines. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Locations Neutral Start Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3115 - Measure resistance between terminals 2+3 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Continuation for all vehicles If specified values are not obtained: - Replace Clutch Vacuum Vent Valve Switch -F36-. NOTE: Note installation position of clutch vacuum vent valve switch in the upper installation bore of mounting bracket. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified values are obtained: Vehicles with 2-pin clutch vacuum vent valve switch - Connect multimeter between terminal 1 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 2-pin connector terminal 1 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch Electrical / Mechanical Repair Wheel Bearing: Electrical / Mechanical Repair Rear Wheel Bearing Press for VW/Audi AST tool# 3420 VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle 2008 suggested user price: 25.92 Assenmacher Specialty Tools 1 800 525 2943 Page 2881 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 2009 Crankshaft: Tools and Equipment Seal Installer - AST Tool # 3265 Seal Installer AST tool# 3265 Seal Installer for front Crankshaft oil seal. Applicable: VW/Audi V6(5V) - Contact AST for pricing - Made in Germany Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 4065 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 4586 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 2492 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 1828 Fuse arrangements in fuse holder, instrument panel left Page 232 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2788 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. J104 - ABS Control Module Electronic Brake Control Module: Locations J104 - ABS Control Module J104 - ABS Control Module - in engine compartment, to left of vacuum brake booster - component of ABS Hydraulic Control Unit Page 5991 S162 - Fuse -1- (30) in fuse bracket/battery S163 - Fuse -2- (30) In Fuse Bracket/Battery S163 - Fuse -2- (30) in fuse bracket/battery S164 - Fuse -3- (30) In Fuse Bracket/Battery Page 200 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 6098 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 827 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. 4 Speed 01M Transmission Fluid - A/T: Testing and Inspection 4 Speed 01M Transmission ATF Level, Checking and Topping Up Special Tools and Equipment - VAG 1551 Scan Tool. - VAG 1551/3 Cable. - VAG 1924 Reservoir. VW ATF is obtainable as a spare part: Container size 0.5 ltr. - Part No. G 052 162 A1. - Container size 1.0 ltr. - Part No. G 052 162 A2. - Always replace seal (arrow) when checking ATF level. 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 5884 - Install battery so lug of battery carrier (arrow) engages in battery foot strip cut-out -1-. It must not be possible to move a battery to the left or to the right. - The battery is correctly installed when the center cut-out in the battery foot strip aligns with threaded hole in the battery carrier (arrows). On batteries with hose for central venting, ensure hose is not kinked. Only then can battery vent freely. - On batteries without hose for central venting, ensure opening on upper side of battery cover is not blocked. - Install clamping bracket and tighten securing bolt -3- (M8 x 25) to 22 Nm (16 ft. lb). - Re-install battery case -2- together with heat protection jacket. - Fasten battery case with securing bolt -1-. - Secure (+) positive terminal clamp -2- to positive terminal on battery. NOTES: The battery terminal clamps may only be secured by hand without force in order to prevent damage to the battery housing. - Battery terminals may no longer be greased. With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 807 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection High Pressure Sensor G65 High Pressure Sensor, Checking The following describes manual checking of High Pressure Sensor G65 using conventional measuring tools. A guided checking procedure is also possible using the VAS 5051/5052 tester in operating mode "Guided Fault Finding". Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of either G65 or F129 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Special tools, testers and auxiliary items required If performing guided test, use VAS 5051/5052 - Applicable wiring diagram - VAG 1767 Ignition tester (or equivalent device capable of duty cycle measurements) - VAG 1594/A (or C) Connector test set - VAG 1598 A Test box - In cases where refrigerant system may need to be recharged, use Kent-Moore ACR (or equivalent, VAG 1885 illustrated for reference only). Prerequisites Workshop temperature: 20-30 ° C (68-86 ° F) - Engine at workshop temperature. Preparation Note: The following test procedure is only possible on vehicles where the G65 square wave signal to Coolant Fan Control (FC) Control Module J293 is Page 3564 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Check wiring between test box and 5-pin harness connector -1- for open circuit according to wiring diagram. Terminal -1- + socket 26 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Check wiring additionally for short circuit to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: Page 2835 L4 Engine W/1 Exhaust Banks & 1 Catalysts Specifications Idle Speed: Specifications Not adjustable 680 to 720 rpm Page 172 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2497 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5679 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 2304 Spark Plug: Tools and Equipment Plug Connector Remover - AST Tool # H 1849-6 Plug Connector Remover AST tool# H 1849-6 Used for spark plug boot removal. Applicable to VW VR6 engine and is comparable to VW tool # T10029. - For the R and R of Spark Plug Connectors - Applicable to VW Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5052 Fig. 3 Removing lock plate for gate selector bracket and gear lever guide/gate selector housing Lift tab in direction of arrow. Page 785 ^ Disconnect wheel speed sensor wiring connector -1-. ^ Remove bolt -2- from wheel bearing housing. ^ Remove wheel speed sensor from wheel bearing housing. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat sensor with lubricant G 000 650. ^ Insert speed sensor into mounting hole in wheel bearing housing and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor wiring connector. ^ Turn wheels fully to left and right lock and check clearance of speed sensor wiring. ABS wheel speed sensor rotor for front axle, checking ^ Raise vehicle. ^ Remove wheel. ^ Rotate brake disc and check whether wheel speed sensor rotor is damaged or dirty. ^ If rotor is damaged, remove wheel hub with rotor and replace. ^ Raise vehicle. ^ Remove wheel. ^ Turn wheel hub and measure distance between rotor and speed sensor, -dimension a, all around. Dimension a = 0.3 mm (0.0118 in.) ^ If the rotor is not true, remove wheel hub with rotor and replace. Page 3491 Select function XX NOTE: The next time the ignition is switched "on" the identification of the engine control module is read by the immobilizer control module and stored. 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 6092 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1790 Refrigerant Oil: Fluid Type Specifications A/C Refrigerant Oil .............................................................................................................................. ........................................................................ PAG Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 3680 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) -G68Removing and Installing VSS -G68Special tools, testers and auxiliary items - Obtain radio code on vehicles with coded radio. - Switch ignition off and disconnect battery ground strap. - Remove battery. - Remove air cleaner. - Install support bar 10-222 A with legs 10-222 A/1 (adapter 10-222 N3 for 6-cyl. engine) and support engine/transmission in position. - Remove bracket for power steering pressure hose. Page 3704 Part 2 Page 3656 Part 1 Page 4399 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 2862 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -3- and -4(harness connector to Engine Control Module (ECM)). - Start engine and run at idle. - Measure voltage supply and observe display group 41, display field 2. Display: Htg.bC.ON Specified value: 11.0-14.5 V Display: Htg. bC.ON/Htg.bC.OFF (alternating) Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 3103 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Page 1566 Alignment: Service and Repair Rear Wheel Camber, Adjusting Rear wheel camber, adjusting Camber cannot be adjusted. If vehicle checks outside of specification, check trim height and adjust if necessary. If specification cannot be obtained, check axle beam for damage and replace if necessary. Toe, Adjusting Rear wheel toe, adjusting If vehicle is out of specification, check trim height and balance if necessary Rear axle total toe is not adjustable Only by sliding brackets is it possible to balance individual toe values. If, after attempting above method, vehicle remains out of specification, check axle beam for damage and replace if necessary Loosen all bolts at bracket -1- Slide bracket -1- laterally. 2. Rear axle beam Tighten bolts 75 Nm (55 ft. lbs.). NOTE: Always use new bolts Page 2319 Removing - Remove engine cover. - Remove center and right insulation trays - Remove ribbed belt See: Drive Belts, Mounts, Brackets and Accessories/Ribbed Belt/Service and Repair - Pull off crankcase breather connecting hose between cylinder head cover and intake hose on cylinder head cover. Note: Press buttons on hose couplings to disconnect - Drain coolant See: Cooling System/Coolant/Service and Repair - Install engine support bracket 10-222A with legs 10-222A/1. - Insert securing hook of supporting device in right lifting eye of cylinder block and put engine under slight tension. - Unbolt engine side of assembly mounting from top of engine bracket -arrows-. Note: Use ladder VAS 5085 to remove securing bolts. - Lower engine on supporting device only as far as necessary to remove coolant pump. - Remove belt pulley. Counter-support belt pulley with water pump wrench VAG 1590 when doing this. Note: If engine has been removed, it is not necessary to remove belt pulley. The coolant pump securing bolts can be unscrewed through the holes in the pulley. Page 4176 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 2456 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Page 1749 using the VAS 5051 The results and diagnostic log must be sent to the Volkswagen Technical Assistance Center (TACS) before any repairs are performed. 4. Advise the customer that if the low oil level warning light comes on before the 630 mile (1014 km) test is completed, the vehicle must be taken directly to the Dealership for part # 2 of the oil consumption test, regardless of the miles accumulated. The customer should not add any oil. Note: Page 5104 Test Step 1 - 2 Page 4817 Part 1 Page 1486 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide Page 3101 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Page 2403 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2745 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 6158 Power Distribution Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 5858 - The construction of the filler support on filling bottle VAS5045 prevents an overfilling of the battery cells and therefore stops electrolyte from leaking out. When the max. level is reached, the flow of distilled water into the battery cells is interrupted. - Use distilled water only. This prevents contamination of the battery electrolyte and the associated increased self discharge. - Reinstall battery cells sealing plug again if necessary. It is absolutely necessary to use original sealing plugs in the battery screwed openings to guarantee the battery is sealed correctly. Use original sealing plugs of same construction if lost or damaged. The sealing plugs must be installed with an O-ring. Electrolyte Level, Checking (Batteries With Charge Indicator) Electrolyte Level, Checking (batteries With Charge Indicator) Special tools, testers and auxiliary items needed - VAS 5045 Battery filling bottle (or equivalent) WARNING! - Refer to Warnings and Safety Measures. - When checking electrolyte level with sealing caps removed, illuminate the inside of the battery housing/cells with a flashlight. - Keep open flames and sparks away. The correct battery electrolyte specific gravity is an important factor in maintaining battery performance and service life. Insufficient electrolyte levels allow cell plates to dry, resulting in a loss of battery capacity (reduced output). If the cell plates are not completely submerged by electrolyte, (sulfuric acid/water mixture) corrosion will occur on the plates, plate bridges and cell connector. Optimum battery function is not possible under these conditions and battery failure results. If electrolyte level is too high, electrolyte (sulfuric acid/water mixture) may leak out and damage the surrounding area, i.e.: plenum and engine compartment. - Switch ignition off Page 5562 Brake Caliper: Service and Repair Rear Brake Caliper Rear brake caliper Notes: ^ When repairing install all parts supplied in repair kit. ^ New brake calipers are filled with brake fluid and pre-bled. ^ Apply a thin coat of assembly lubricant, Part No. G 052 150A2, to brake cylinders, pistons and seals. ^ When repairing, it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installation in the vehicle 1 Self-locking hex bolt, 35 Nm (26 ft. lbs.) ^ Always replace ^ When loosening and tightening counterhold on guide pin 2 Bleeder valve ^ Apply a thin coat of assembly lubricant G 052 1 50 A2 to threads before installing 3 Dust cap 4 Guide pins ^ Grease before pulling on protective cap 5 Protective cap ^ Pull onto brake carrier and guide pin 6 Brake carrier with guide pin and protective cap ^ Replacement part is assembled with sufficient grease on guide pins ^ If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate the guide pins. 7 Protective seal ^ Pull outer sealing lip onto piston Page 44 - Antenna cables - New Beetle with Satellite radio (convertible) - Antenna cables - W8 Passat Page 1294 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1248 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Continuation Page 2572 Production Solution No production change required. Service Tip: Oil level MUST be correct, if overfilled, level should be adjusted to the proper level prior to performing procedure. Adjusting oil level is NOT covered by Warranty. Exhaust system damage from outside influences is NOT covered by Warranty. The following steps are to be followed before replacement of catalytic converters. Inspect complete exhaust system for broken or missing components, loose clamps, etc. Repair as necessary. If vehicle has MIL ON, investigate fault memory without erasing codes. Before performing any repair, make a print out of fault memory including: Address 01 fault memory (including ECM information) Address 01 Measuring Value Block 46 (and 47, if applicable) Tip: For 4 bank systems such as Phaeton W12, Display groups 46 and 47 must be printed out from addresses 01 and 11. OBD freeze-frame mode 2, and 6. Tip: For OBD, see Repair Manual - Fuel Injection & Ignition 2.0 Liter 4yl. 2V Generic Scan Tool Engine Code(s). AEG, BBW, BEV, ST-Generic Scan Tool Steps for printing OBD from the touch screen: Select "OBD". Select "mode 2". Select all PIDS displayed (use scroll bar if necessary). Select right arrow key to display results. Select "print", and then save result. Save results for modes 2 and 6. Print - self diagnosis log. DO NOT replace catalyst if software updates related to catalyst are available. Check for applicable Technical Bulletins or Campaigns. Perform any applicable software updates available through Technical Bulletins or Campaigns. If other faults related to fuel mixture, oxygen sensor or misfire are present: DO NOT replace catalyst(s). Correct condition, erase DTCs, reset readiness codes and monitor measured value block (MVB) in 46, 47 until complete ("Test OK or Test n OK"). If after repair of other faults, diagnostic result in MVB 46 (and 47, if applicable) is/are OK: DO NOT replace catalyst(s). Page 6127 Recall 07V063000: Brake Light Switch Replacement Brake Light Switch: Recalls Recall 07V063000: Brake Light Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 1999-2006 Volkswagen/GTI 1999-2006 Volkswagen/Jetta 2001-2005 Volkswagen/New Beetle 2001-2007 Volkswagen/R32 2004 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V063000 MFG'S REPORT DATE: February 15, 2007 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 790000 SUMMARY: On certain passenger, wagon, and convertible vehicles equipped with or without cruise control, a brake light switch may malfunction if it was installed incorrectly. CONSEQUENCE: The brake lights could become inoperative, or remain on. Failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before April 27, 2007. Vehicles within the make, model, and model year of this population may be involved in either this recall or 06V-183, but not both. The remedy is the same for each recall. Volkswagen dealers will apply the remedy based on the VIN number of the vehicle. Owners may contact VW at 1-800-822-8987. NOTES: Volkswagen recall No. N4. Customers may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Page 5332 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 4314 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5233 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Page 2580 Production Solution No production change required. Service Tip: Oil level MUST be correct, if overfilled, level should be adjusted to the proper level prior to performing procedure. Adjusting oil level is NOT covered by Warranty. Exhaust system damage from outside influences is NOT covered by Warranty. The following steps are to be followed before replacement of catalytic converters. Inspect complete exhaust system for broken or missing components, loose clamps, etc. Repair as necessary. If vehicle has MIL ON, investigate fault memory without erasing codes. Before performing any repair, make a print out of fault memory including: Address 01 fault memory (including ECM information) Address 01 Measuring Value Block 46 (and 47, if applicable) Tip: For 4 bank systems such as Phaeton W12, Display groups 46 and 47 must be printed out from addresses 01 and 11. OBD freeze-frame mode 2, and 6. Tip: For OBD, see Repair Manual - Fuel Injection & Ignition 2.0 Liter 4yl. 2V Generic Scan Tool Engine Code(s). AEG, BBW, BEV, ST-Generic Scan Tool Steps for printing OBD from the touch screen: Select "OBD". Select "mode 2". Select all PIDS displayed (use scroll bar if necessary). Select right arrow key to display results. Select "print", and then save result. Save results for modes 2 and 6. Print - self diagnosis log. DO NOT replace catalyst if software updates related to catalyst are available. Check for applicable Technical Bulletins or Campaigns. Perform any applicable software updates available through Technical Bulletins or Campaigns. If other faults related to fuel mixture, oxygen sensor or misfire are present: DO NOT replace catalyst(s). Correct condition, erase DTCs, reset readiness codes and monitor measured value block (MVB) in 46, 47 until complete ("Test OK or Test n OK"). If after repair of other faults, diagnostic result in MVB 46 (and 47, if applicable) is/are OK: DO NOT replace catalyst(s). Page 5234 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Page 290 Owner Letter Page 5230 Test Step 5 - 6 Front Wheel Bearing: Service and Repair Front Wheel Bearing, Servicing II - Wheel bearing, servicing Special tools, testers and auxiliary items required ^ Thrust plate VW401 ^ Punch VW407 ^ Punch VW408A ^ Punch VW412 ^ Thrust tube VW432 ^ Thrust tube VW442 Page 3713 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 3518 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Page 3273 Diagrams/Electrical Diagrams/Master Diagram Index Diagram 74/4 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Page 2747 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Power Supply and Cables Check Electronic Throttle Control Module: Testing and Inspection Power Supply and Cables Check Checking the power supply and cables to the control module - Remove driver side shelf: - Disconnect 6 pin connector for throttle position sensor. - Turn on ignition. - To measure voltage, connect multimeter to following contacts of connector: Contact 1 + ground - Contact 1 + 5 - Contact 2 + ground - Contact 2 + 3 - Specification: at least 4.5 V - Turn off ignition. If the specifications are not achieved: - Connect VAG 1598/31 test box to control module wiring. Do not connect engine control module. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection A/C Pressure Switch F129 A/C Pressure Switch, Electrical Checks Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10.8mm x 1.8mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan V7 (via the coolant fan control module J293 ) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). A/C Pressure Switch, Functional Checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch N25 engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), F129 switches A/C clutch off. - Check cooling fan function. When system pressure increases, F129 causes coolant fan V7 to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condensor is blocked), F129 switches A/C clutch off. Page 3266 Part 2 Page 203 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4615 Seals and Gaskets: Service and Repair 5 Speed Automatic 09A Differential Side Seal, Automatic Transaxle Model 09A Oil seals for flanged shafts, replacing (Transmission in vehicle) Oil seal for left flanged shaft, replacing Special tools and equipment VW771 Multipurpose tool - VW771/37 Puller hooks - V.A.G 1306 Drip tray - V.A.G 1331 Torque wrench - V.A.G 1332 Torque wrench - T10087 Thrust piece Removing left-hand flange shaft seal Page 4588 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Page 5188 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3946 NOTE: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator: - Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. - Switch ignition off. - Now check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow -arrow-). - Observe pressure drop on pressure gauge. If pressure does not drop: - Test check-valve of Fuel Pump (FP), Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking If pressure does drop again: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator: Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. If pressure does drop again: - Check whether line connections, O-rings in fuel rail, and fuel injectors are properly sealed. - Check whether pressure gauge is properly sealed. NOTE: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. Page 3845 Explanation of 8 digit number block If the specified value is obtained: - Briefly increase engine speed (rev- up) and allow engine to run at idle for 2 minutes. Checking idle speed - Change to display group 056 as follows: - Press -C- button. - Press buttons -0-, -5- and -6- to input display group number 56 (056) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 56 -> 1234 - Check actual idle speed in display field 1. - Check specified idle speed in display field 2. - Check operating mode in display field 4. Explanation of 5 digit number block Page 5739 Electronic Brake Control Module: Diagrams ABS Control Module (w/EDL) Page 4224 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 2010 Crankshaft: Tools and Equipment Crank Seal Installer - AST Tool # 3266 Crank Seal Installer AST tool# 3266 Used to install Crankshaft oil seal (Vibration damper end). - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 1811 Fuse arrangements in fuse holder, instrument panel left Fuse Arrangements In Fuse Bracket/Battery Page 234 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 4016 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 3082 Part 2 Page 4017 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3834 - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Vehicles with engine code BDF - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. Page 1541 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 852 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Switch F38 - Ambient temperature switch Page 469 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3678 Vehicle Speed Sensor: Testing and Inspection With Generic Scan Tool Checking Speed Signal Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Battery voltage must be at least 11.5 volts. - Speedometer -G21- must be OK. Test sequence NOTE: To test speed signal, vehicle must be driven. Doing this requires a second person. WARNING: Secure Scan Tool (ST) on the rear seat and have operated from there by second technician. - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 13: Vehicle speed". - Perform a road test, and have the 2nd person observe the indication on the display. - Check specified value of the vehicle speed: - End diagnosis and switch ignition off. If no speed is indicated: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - To measure voltage, connect multimeter between sockets 2 (Ground -GND-) +54 (speed signal) of test box. - Raise vehicle at front left. - Switch ignition on. - Rotate front wheel, and observe voltage indicated while doing so. Specified value: 0.0 to at least 4.0 V, fluctuating NOTE: The right front wheel must not turn during this, hold it steady if necessary. System Pressure Fuel Pressure: Specifications With Hose to Regulator Connected approx. 2.5 bar With Hose to Regulator Disconnected approx. 3.0 bar Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Vehicle - Hesitates or Won't Move After Stopping Electronic Throttle Actuator: Technical Service Bulletins Vehicle - Hesitates or Won't Move After Stopping Group: 01 Number: 01-01 Date: Mar. 29, 2001 Subject: Customer States, "Vehicle Hesitates or Will Not Move After Stopping" Model(s): All with Electronic Throttle Control and Auto. Trans. Condition Customer complains that vehicle hesitates or will not move after activating accelerator pedal. May be caused by customer applying the brake pedal and accelerator pedal at the same time. Customers who drive with their left foot resting on the brake pedal are prone to experience this condition. Service With the introduction of electronic throttle control "E-gas" (no accelerator cable) to fuel injection systems, an engine RPM control feature has been incorporated into the engine electronic control system software. Application of both brake and accelerator pedals at the same time e.g., brake pedal with left foot and accelerator pedal with right foot results in the following: ^ Brake pedal function (normal at all times) overrides any throttle application. ^ Engine RPM's will return to idle if the brake pedal is applied while accelerator pedal is depressed. ^ Will NOT cause DTC's to be stored. Note: Full engine RPM control is immediately returned to the driver when brake pedal application is terminated and (accelerator pedal is rapidly applied or if foot is lifted off the accelerator pedal and then re-applied to accelerator pedal). - Test drive vehicle with customer to duplicate condition. - During test drive observe customer's driving habits to determine if customer drives and/or brakes with his/her left foot. - Check for any stored DTC's. If DTC's are found: - Repair as necessary per Repair Manual. If NO DTC's are found: - Explain the following to the customer: ^ The hesitation is due to the left foot resting on or applying the brake pedal and trying to accelerate. ^ If applied at the same time, the brake pedal overrides the accelerator pedal application (causing hesitation). ^ It is best not to drive with the left foot resting on the brake pedal. Also explain that the accelerator control function will return when: ^ The left foot is taken off the brake pedal and the accelerator pedal is rapidly applied. ^ The left foot is taken off the brake pedal and the right foot is lifted off the accelerator pedal, then re-applied to accelerator pedal. Page 4171 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Page 2481 Radiator: Service and Repair Auxiliary Radiator Auxiliary radiator Removing - Drain coolant, refer to Coolant - Service and Repair - Procedures See: Coolant/Service and Repair - Remove right front sound-proofing mat, refer to Body and Frame - Sound Proofing/Insulation - Service and Repair - Procedures See: Body and Frame/Sound Proofing / Insulation/Service and Repair/Procedures - Remove fender liner, front right, refer to Body and Frame - Fender - Inner Fender - Service and Repair - Procedures See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair - Remove front right air outlet, refer to Body and Frame - Bumper - Bumper Cover, Fascia - Service and Repair - Procedures See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair Remove windshield washer reservoir, refer to Wiper and Washer Systems - Windshield Washer Reservoir - Service and Repair - Procedures See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair - Using pliers for spring band clips ((VAG 1921), pull coolant hoses off auxiliary radiator in engine compartment below right headlight (arrows). - Remove upper retaining screws -1- of auxiliary cooler. With Manufacturer's Scan Tool Canister Purge Control Valve: Testing and Inspection With Manufacturer's Scan Tool EVAP Canister Purge Regulator Valve (N80), Checking The solenoid valve is closed when there is no current. Special tools, equipment, test and inspection devices; required accessories - V.A.G1551 scan tool NOTE: The VAG 1552 scan tool may also be used in place of the V.A.G 1551 scan tool, except that no printout can then be made. - V.A.G 1551/3 cable Test conditions Page 726 4 - Coupling station - Installation position: B-pillar - Remove B-pillar lower trim to remove 5 - Door control module, RR For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 6 - Door lock, RR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 7 - Motor for fuel tank lid unlock -V155- remote release Installation position: Under C-pillar trim - To remove, remove trim up to wheel house - Remove with special socket insert T 10010 8 - Rear lid lock Bolted to rear lid - Removing: Remove trim from rear lid. - Remove lock. 9 - Rear lid actuator Bolted to rear lid - Remove with special socket insert T 10010 10 - Door lock, RL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 11 - Coupling station Installation position: rear roof area, covered by roof trim - Remove roof trim to remove. 12 - Anti-theft alarm horn Installation position: In area of C-pillar covered by trim 13 - Door control module, RL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 14 - Coupling station Installation position: B-pillar - Remove B-pillar lower trim to remove 15 - Door lock, FL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 16 - Controls Installed in door trim - Remove door trim to remove 17 - Door control module, FL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 18 - Antenna - for radio frequency remote control - Under left A-pillar trim - Remove A-pillar trim to remove. 19 - Coupling station Page 1218 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Page 4587 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Page 6149 Illustration shows grounding strap already installed. - Insert end -A- of ground strap through slot in tab up to bend -B- at other end of strap. - Bend down tab on inside of fuel filler pipe. This will secure strap to end of tab. - Reinstall fuel filler cap. Warranty Information only. Required Parts and Tools Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 2357 ALWAYS perform complete repair as outlined in this Technical Bulletin. DO NOT skip steps or fail to replace parts as instructed. Parts required: See Required Parts and Tools. Wiring repair, general procedures 1. Review instruction manual included in VAS 1978 wiring repair kit. 2. ONLY use parts included in this kit. if supplemental wiring terminals or supplies are required, use only materials from the VAS 1978 kit. Wiring, making splice connections 1. All wiring splice connections MUST be made using the VAS 1978/1 crimping tool with either the VAS 1978/24 crimp tool die for connections using (light yellow) crimp connector Part No: 111971941 A, or the VAS 1978/2 crimp tool die for connections that utilize other crimp connectors. 2. All wiring splice connections MUST be heat shrunk and sealed using the hot air blower from the VAS 1978 kit and the VAS 1978/15 adapter. 3. When required, strip wiring ends using the VAS 1978/3 wire stripper (this minimizes possibility of broken wire strands). Unused wiring, taping back to harness During this repair, ALL unused wires in the vehicle must be terminated using a cut, stretch, fold, and tape technique as follows: This prevents unused wires from coming in contact with ground or any other circuit. ^ Cut wires with suitable wire cutters. ^ Stretch (pull) wire insulation with pliers to extend slightly beyond end of wire strands. ^ Fold wire over upon itself. ^ Tape wire using vinyl tape. Wiring terminals and seals, removing and installing in connectors 1. Removal of terminals from 10 or 14 pin engine harness connector or fuel pump connector (if needed) must be performed using the VAS 1978/4a. 2. Insertion of the single wire seals on 10 or 14 pin engine harness connector or fuel pump connector (if needed) must be performed using the appropriate seal tool from VAS 1978 kit. Vehicle, Preparation The following should be performed prior to installation of the repair kit. ^ Obtain radio code, odometer adaptation readings. ^ Disconnect battery Ground (GND) cable. ^ For MY 2001 vehicles, remove battery (see Repair Manual, Group 27). ^ Remove windshield washer reservoir. ^ Loosen fuel and evaporative emission tube housing from strut tower. ^ Remove windshield wipers and plenum cover (see Repair Manual, Group 92). ^ Cut and remove three tie wraps holding engine harness to firewall in plenum. ^ Remove wiring harness (cable) channel cover on left side of engine compartment (see Repair Manual, Group 97). ^ Disconnect 10 Pin (MY 1999 vehicles) or 14 pin (MY 2000 vehicles) connector in wiring harness channel (MY 2001 vehicles below battery). ^ Remove instrument panel (see Repair Manual, Group 70). CAN-Bus, Checking Engine Control Module: Testing and Inspection CAN-Bus, Checking With Manufacturer's Scan Tool Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. Page 4783 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1152 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1829 Fuse: Application and ID Fuse Arrangements In Fuse Bracket/Battery Fuse arrangements in fuse bracket/battery A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation A/C Pressure Switch F129 A/C Pressure Switch F129 F129 has three functions: Switches the A/C clutch N25 off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged). - Switches the A/C clutch N25 off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out) - Switches on the second speed coolant fan V7 when refrigerant circuit pressure increases. Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. - A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Spark Plug Pliers - AST Tool # H 1849 Spark Plug: Tools and Equipment Spark Plug Pliers - AST Tool # H 1849 Spark Plug Pliers AST tool# H 1849 Used for the R and R of spark plug connectors and specifically for those with anti-heat terminals. These Pliers are applicable to Mercedes models 190 E and 300 E, and VW/Audi. - Spark Plug Pliers - Applicable to Mercedes, VW and Audi - Steel Construction and Easy-Grip Handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 4580 Test Step 12 Page 2865 Display Group 034 If the specified values are obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specified values are not obtained: - Carry out road test to free oxygen sensor of possible residues and repeat test. Observe the safety precautions when carrying out a road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: Page 6460 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Raise vehicle. - Remove wheel. - Reset brake - To do this use a screwdriver through the opening in brake drum and push adjuster upward. - Remove phillips-head screw for brake drum and take out brake drum. - Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove 12-point nut. Page 6580 Ambient Temperature Sensor / Switch HVAC: Locations Ambient Temperature Switch F38 - Ambient temperature switch Page 5593 ^ Turn ignition switch to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics" ^ Select "07 - Code control unit" <-- Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J ^ Press the "Q" button to confirm Note: On the display, in the upper right corner, the control module part number and coding are displayed ^ Press <-- button ^ Select "06 - End output" ^ Disconnect VAS 5051 from vehicle ^ Recode radio and reset radio preset stations ^ Reset clock ^ Where applicable, reset power window pinch protection ^ Turn ignition to "OFF" position ^ Proceed to Section E Section E Section E - Brake Bleeding ^ Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING! Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 Note: Page 6141 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 6043 Power Distribution Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 6450 Special tools, testers and auxiliary items required ^ Thrust pad 40 - 105 ^ Press tool 3283 ^ Collar for wheel bearing inner race 3423 ^ Engine and transmission jack V A.G 1333 A with universal transmission mount V.A.G. 1359/2 ^ - 2 - Puller Kukko 18/0 Special tools, testers and auxiliary items required ^ Foot pump with high pressure hose V.A.G. 1389A/1 If there is a hand pump V.A.G. 1389/1 available in the dealership it can be converted to a foot pump. To do this use the conversion kit V.A.G. 1389/4. Locations Power Protection Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1674 Note: Cooling system flushing due to coolant mixing or incorrect coolant is not covered by warranty. Warranty Information Only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 6339 Part 1 Page 3614 Display Group 032 Initiating learning process: Control module in Basic Setting scan tool function 04. Learning prerequisites for idle speed: - Idle speed - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C Instruments - Various Instrument Cluster Malfunctions Coolant Reservoir: All Technical Service Bulletins Instruments - Various Instrument Cluster Malfunctions 97 07 03 May 3, 2007 2002270, Supersedes Technical Bulletin Group 97 number 01-01 dated April 30, 2001 due to inclusion into ElsaWeb. Condition Vehicle Information Wiring Harness, Coolant Contamination at Instrument Cluster Contamination can result in various malfunctions of the instrument cluster. Technical Background Coolant leaking from coolant reservoir bottle wiring connector contaminates the wiring harness. Production Solution Improved coolant reservoir bottle. Service If an instrument cluster exhibits a malfunction: ^ Record Vehicle Mileage (odometer adaptation reading) (see Repair Manual). ^ Print out any and all instrument cluster coding and adaptation values using the VAS 5051/5052 for use after repairs are complete. ^ Remove instrument cluster (see Repair Manual). ^ Remove blue flat contact housing cover and inspect wire terminals for moisture or corrosion. If moisture or corrosion is found (arrow): ^ Repair wiring using repair kit 1JM998001. This kit contains overlay harnesses, splice connectors, tape and installation tube necessary to repair the affected harnesses. The instrument cluster, coolant bottle and fuel pump/fuel sender must also be replaced. IMPORTANT! Oxygen Sensor and O2 Sensor Control After TWC, Checking Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control After TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (After Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair terminals 3 and 4 in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head free of leaks - Coolant temperature at least 85 °C = display group 04, display field 3 Functional check - Press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle (connecting scan tool and selecting engine electronics control module. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -3-, and -0- to input display group number 30 (030) and press - Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 - Check status of oxygen sensor control after Three Way Catalytic Converter (TWC) (display field 2). Page 175 Power Seat Control Module: Service and Repair 8-way Seat Control Module, Removing And Installing NOTE: Control module is installed under drivers seat. Removing - Remove seat. - Disconnect four harness connectors - arrows -. - Remove bolts - 1 - and - 2 -. - Remove control module - 3 -. Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Page 2596 Exhaust Manifold: Service and Repair For further information regarding this component please refer to Exhaust Systems; Service and Repair. A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 2008 T 40047 - Setting Gauge Page 77 - Antenna Selection Control Module -J515- (Diversity box) -3-: ^ Location Wagon; behind left luggage compartment side trim, below rear side window. ^ Location, Sedan: under rear parcel shelf. Antennas: All models use four antennas -1-, -8-. ^ Location Wagon: Integrated with rear side windows. ^ Location Sedan: Integrated with rear window. Antenna amplifiers: All models use four antenna amplifiers -2-. ^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows. ^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim. Touareg Fuel System - Fuel Related Driveability Issues Fuel: Technical Service Bulletins Fuel System - Fuel Related Driveability Issues 0109-01 Affected Vehicles Condition 01 09 01 Jan. 08, 2009 2014815 Supersedes T. B. Group 01 number 07-55 dated July 17, 2007 due to additional models and model year applicability. Gasoline Quality The use of contaminated gasoline, seasonal fuel changes (summer/winter fuel) or gasoline with a low content of deposit control additives may result in one or more of the following conditions: Excessive accumulation of deposits on intake valves, intake manifold, fuel injectors and combustion chambers. Engine runs rough after cold start. Excessive engine cranking time. Stumbles while driving. Rough engine idle. Loss of engine performance. Poor fuel economy. Conditions may be severe enough to illuminate the MIL in conjunction with storage in the ECM data memory of DTCs for misfire (example: P0300, P030x) and / or lean fuel system (example: P0171, P0174, P1128, P1130, P1136, P1138). Technical Background 1. Condition may be caused by use of contaminated gasoline. 2. Condition may be caused by use of gasoline with a low content of deposit control additives. Production Solution No production change required Service 1. If use of contaminated gasoline is suspected: Consider advising the customer to change gasoline source (brand/gas station). Contaminated gasoline may exhibit one or more of the following characteristics: - May have unique color and odor. - May contain water. - May contain sediments and suspended matter. - May appear cloudy and (after settling) may show signs of separation. If use of gasoline with a low content of deposit control additives is suspected: Recommend to the customer the exclusive use of TOP TIER Detergent Gasoline. These products provide improved deposit control performance. Current TOP TIER Gasoline retailers offering this product in all their octane grades include the following brands: QuikTrip Chevron Conoco Phillips 76 Shell Entec Stations MFA Oil Company Kwik Trip/Kwik Star The Somerset Refinery, Inc. Chevron-Canada Aloha Petroleum Tri-Par Oil Company Shell-Canada ATF Level Checking and Topping Up Final Drive Fluid: Testing and Inspection ATF Level Checking and Topping Up 4 Speed Automatic 01M ATF Level Checking and Topping Up Special Tools and Equipment - VAG 1551 Scan Tool. - VAG 1551/3 Cable. - VAG 1924 Reservoir. - VW ATF is obtainable as a spare part: ‹› Container size 0.5 ltr. (0.53 qt) - Part No. G 052 162 A1. ‹› Container size 1.0 ltr. (1.0567 qt) Part No. G 052 162 A2. Page 300 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 4002 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5499 8 Piston with - automatic adjustment ^ Apply thin coat of assembly lubricant G 052 150A2 to piston before inserting 9 Sealing ring ^ Removing and installing 10 Brake caliper housing with parking brake cable lever ^ If a leak exists at the parking brake cable lever replace brake caliper housing ^ After repairing, pre-bleed caliper housing Rear brake caliper piston, removing and installing Special tools and equipment required ^ 3272 Piston resetting and removal tool ^ 3409 Wedge ^ Bleeder bottle Removing ^ Remove piston from brake caliper housing by turning knurled wheel counterclockwise. Notes: ^ Install special tool 3272 with the collar (arrow) positioned before the piston. ^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow-A-) provided for this purpose. Page 1759 Ch-Fu Page 4528 Fig. 8 Removing and installing transmission vehicle speed sensor Location: Transmission vehicle speed sensor -arrow- is located on top of the transmission. Switch ignition off, open hood. - Disconnect wiring connector from sensor. - Remove bolt and pull sensor out. - Replace seal. Installation is performed in the reverse order of removal. Tighten bolt to 10 Nm. Fig. 9 Removing and installing vehicle speed sensor -G68- with transmission installed Location: Vehicle speed sensor-arrow- is located on top of the transmission. When the transmission is installed the sensor is covered by the left assembly mounting. Obtain radio code on vehicles with coded radio. - Switch ignition off and disconnect battery Ground strap - Remove battery. - Remove air cleaner. Page 3624 - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -3-, and -4- to input display group number 34 (034) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 34 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by the Engine Control Module (ECM). - Check specified values in display fields 1-4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 2235 Timing Chain: Service and Repair Valve Timing, Checking Special tools, equipment, test and inspection devices; required accessories - 3268 Camshaft guide - T10029 Assembly tool Test sequence - Remove valve cover. - Using mounting bolt for vibration damper, align crankshaft with TDC cyl. 1 position -arrow- by turning in direction of rotation of engine. Camber, Adjusting, Front Wheel Alignment: Service and Repair Camber, Adjusting, Front Wheel Front wheel camber, adjusting Camber cannot be adjusted If vehicle is out of specification, check trim height and balance if necessary By adjusting sub-frame it is possible to bring camber within tolerance. - Loosen bolts -1- and -2-. - Move sub-frame to equalize camber on both sides. - Check caster; caster can also change when moving sub-frame. NOTE: Always replace sub-frame bolts (one at a time) when making this type of adjustment. Tightening torque Support to body 100 Nm (74 ft. lbs.) + turn 90° Bolt position -1- Use new bolts! Support to body 100 Nm (74 ft. lbs.) + turn 90° Bolt position -2- Use new bolts! Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Keyless Entry/Starting - Emblem On Remote Damaged Keyless Start Transmitter: All Technical Service Bulletins Keyless Entry/Starting - Emblem On Remote Damaged 57 08 12 Nov. 6, 2008 2017009 Supersedes T.B. Group 57 Number 08-02 dated Feb. 14, 2008 to include additional model years. Vehicle Information Condition Key Remote, Emblem (Sign) Damaged VW emblem on remote key is damaged. Technical Background Due to an insufficient finish, the emblem surface may be damaged (scratched) when in contact with other objects. Production Solution Improved finish on emblem supplied with vehicle production as of (CW) 45/2007 (see sticker on B-Pillar for production date). Service EMBLEM REMOVAL WARNING: Make sure your hands are properly positioned out of the way in case the awl slips. Page 2427 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 6471 Axle Nut: Specifications Rear 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace Page 2397 also transmitted to the Motronic Engine Control Module (ECM). Confirm G65 circuit using wiring diagram. - On vehicles where G65 is NOT connected to the ECM, connect green clip from VAG 1767 directly to G65 pin 2 using appropriate VAG 1594 adapter cable - 7 - . Proceed directly to checking. - Disconnect engine harness electrical connection from Engine Control Module (ECM) - 3 - . - Locate correct test box VAG 1598A - 4 - and adapter according to pin assignments of ECM - 3 and connect test box to engine wiring connector/harness - 2 - . - Connect black clip from VAG 1767 to Ground (GND) - 5 - . - Determine applicable G65 signal input pin assignment to ECM using wiring diagram. Example: T121/61 Note: As G65 function primarily controls coolant fan and A/C clutch operation, the engine wiring diagrams may indicate the G65 signal connection as being "Coolant fan control module connection" . - ECM terminal number assignments correspond with those on test box VAG 1598A . - Connect green clip from VAG 1767 to the corresponding numbered position on test box VAG 1598A connected to G65 pin - 2 - using appropriate VAG 1594 adapter cable - 7 - . Example: 61 Checking Switch ignition on. - Press button - arrow - for Duty Cycle measurement (modulation ratio) on ignition tester VAG 1767 (or select same function on equivalent device). Evaluating results Note: If a malfunction cannot be located, check DTC memory of Engine Control Module (ECM) and the Transmission Control Module (TCM) using VAG 1551/1552/1552 . When doing so, note that DTCs related to sensor G65 functions may be called-out as "A/C pressure switch -F129-" . Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 1268 Display Group 034 If the specified values are obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specified values are not obtained: - Carry out road test to free oxygen sensor of possible residues and repeat test. Observe the safety precautions when carrying out a road test. Refer under "Fuel Delivery and Air Induction", See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (Automatic transmission) Page 4617 Installing left-hand flange shaft seal - Drive in new seal until thrust piece contacts stop. Ensure that seal remains straight when driving. - Insert flange shaft. - Apply sealant D 176 404 A2 to head of countersunk bolt. - Secure flange shaft with countersunk bolt. - Connect ball joint to control arm using new bolts onto old impression marks. - Bolt left-hand drive shaft to flange shaft. - Install wheel. - Check and top up ATF level with transmission installed. - Install sound insulation tray. Tightening torques Flanged shaft to transmission (conical 25 Nm head bolt) Drive shaft to flanged shaft: Refer to Drive Axles, Bearings and Joints. Ball joint to control arm: Refer to Steering and Suspension. Wheel bolts to wheel hub: Refer to Steering and Suspension. Oil seal for right flanged shaft, replacing Page 4740 - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Pry selector lever cable -3- off selector lever -2 with a screwdriver. - Pull out selector lever cable locking plate -1- on mounting bracket downward. - Pull selector lever cable carefully out of mounting bracket. Installing Check the protective sleeve for damage; the protective sleeve can only be changed together with the selector lever cable. - Check that the protective sleeve is correctly tiffed. Do not install the protective sleeve twisted. - Do not bend or kink the selector lever cable. - Selector lever and lever/selector shaft are in "P" position, the front wheels are blocked. - Insert selector lever cable -3- in mounting bracket and press onto selector lever -2-. - Fit new selector lever cable locking plate -1- on mounting bracket. Installation position: Angled end of locking plate must point toward end of selector lever cable. Shift selector lever from "P" to "2". Selector lever mechanism and selector lever cable must move freely. If necessary replace selector lever cable or service selector lever mechanism. - Shift selector lever into "P" position. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. Page 4672 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 1060 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4268 NOTE: If, during the "Update - Programming", a fault message is displayed: - Confirm that VAS 5051 or VAS 5052 diagnostic tool power supply is adequate and that ALL appliances with high electromagnetic radiation (i.e. mobile phones) are switched OFF. - The "Update - Programming" (flashing) process must then be started from the beginning using the "Repeat" button (arrow). DO NOT use the "Cancel" button. IMPORTANT! On NO occasion should the "Cancel" button be selected. Once "Update - Programming" (flashing) is complete: ^ Similar screen appears. ^ ECM Part Number and old software level is still displayed at (arrows). Note: New software level is not displayed until process is complete and fault memories have been erased; - Select the "Print", then "Screen" button. ^ VAS 5051 will print to printer immediately. ^ VAS 5052 will hold the print until process is complete and then you may take the tester to the printer for printing the screen. - Attach print to vehicle Repair Order. Once "Update - Programming" (flashing) is complete, the control module must be re-initialized. - Select the --> button. Page 1898 11. Ball joint ^ Checking; Refer to Ball joint; Testing and Inspection 12. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 13. Shield plate 14. Hex bolt, 10 Nm (89 in lb) 15. Hex bolt ^ For special model "Golf GTI 132 kW" ^ Always replace 16. Self-locking 12-point nut ^ Always replace 17. Phillips screw, 4 Nm (35 in lb) 18. Ventilated brake disc 19. Wheel hub with speed sensor rotor ^ Rotor is welded to wheel hub 20. Circlip ^ Make sure seated correctly 21. Wheel bearing ^ Pressing wheel bearing out of wheel bearing housing ^ Replace, as it is destroyed during pressing out ^ Pressing wheel bearing into wheel bearing housing 22. Wheel bearing housing For vehicles: ^ With gasoline engines from 110 kW (147.5 Hp) Pressing wheel hub out of wheel bearing housing Page 5591 <-- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit ^ Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION! DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE <-- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) ^ Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws Note Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation ^ Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs) Note Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean ^ Remove yellow plastic plugs and red bracket from hydraulic unit ^ Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) ^ Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on atleast2morevehicles.Only one repair kit will be allocated for every 3 vehicles ^ Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) ^ Remove lint-free clothes from under the ABS control module and hydraulic unit Page 2050 Finishing intake valve seat a = dia. 38.3 mm b = max. allowable finishing measurement c = 1.4 - 2.0 mm If necessary, finish valve seat ring with 75° valve reseating tool Z = bottom edge of cylinder head cr = 45° valve seat angle P = 30° correction angle upper -= 60° correction angle lower Finishing exhaust valve seat Page 3170 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Measure resistance from throttle valve drive between terminals -3- and -5- Specified value: 1.0-5.0 ohms If the specified value is not obtained: - Replace throttle valve control module - J338- , item 10. Refer to "Intake Manifold Upper Section, Disassembling and Assembling" under "Fuel Delivery and Air Induction/Variable Induction System", - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt Engine Control Module (ECM) to throttle valve control module. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check accelerator pedal sensor. If the voltage supply and wiring is OK: - Replace Engine Control Module (ECM). Checking voltage supply and wiring to control module Page 541 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 3782 Warranty Required Parts and Tools When replacing any catalyst, your VIN may be required to ensure the correct part is ordered (check with your parts department). No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 5194 Shift Interlock Solenoid: Service and Repair 5 Speed Automatic 09A Shift lock solenoid -N110-, removing and installing Removing Check whether a coded radio is fitted. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - Switch ignition off and disconnect battery Ground strap. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - -Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Unclip shift lock solenoid -N110- from retainer arrows A-. - Pull solenoid out of locking pawl -arrow B-. Page 4937 - Completely grease hole with Molykote grease. - Molykote grease, G 052 723 A2 - Use grease packet from repair kit - Install wheel bearing -1 - - press piece - 2 - install with collar in bearing) and piston cylinder - 3 with pull rod on wheel bearing housing. - Install thrust piece - 4 - with wide collar toward wheel bearing housing and special nut - 5 - on inside. - Press wheel bearing in by operating pump. - Insert circlip with needle nose pliers. 1 - Wheel bearing 2 - Thrust tube E-13-1 3 - Piston cylinder HKZ-15 4 - Thrust tube E-10 5 Special nut E-8-214 and pull rod Pressing in wheel hub - Install hub - 1 - and piston cylinder - 2 - with pull rod on wheel bearing. - Install special nut - 4 - and thrust piece - 3 - (with collar toward special nut) on inside. - Press in hub by operating the pump. 1 - Wheel hub 2 - Piston cylinder HKZ-15 3 - Thrust tube E-5 4 - Special nut E-8-214 and pull rod Further installation is in the reverse sequence to removal. Page 4787 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 4177 Test table Page 6474 6500-17 - 17mm Allen Socket 6500 X-30 - 30mm, 12-Pt. Socket Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Page 3784 L4 Engine W/1 Exhaust Banks & 1 Catalysts Page 1635 - Remove mounting screw(s) -arrow-. - Lift engine covers -A- and -B- (where applicable) from engine. 2.8L - 4V - Unclip and lift engine cover -1- from engine. - Mark running direction of ribbed belt if it will be used again. - Install hex bolt -A- as illustrated and tighten until ribbed belt tension is relieved. - Remove ribbed belt. Ribbed belt, installing Page 766 Lateral Accelerometer: Locations ESP-Sensor Unit (Vehicles With ESP) G419 - ESP-Sensor Unit (vehicles with ESP) Page 5596 Page 3651 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 3275 This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Page 6178 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 6503 - Completely grease hole with Molykote grease. - Molykote grease, G 052 723 A2 - Use grease packet from repair kit - Install wheel bearing -1 - - press piece - 2 - install with collar in bearing) and piston cylinder - 3 with pull rod on wheel bearing housing. - Install thrust piece - 4 - with wide collar toward wheel bearing housing and special nut - 5 - on inside. - Press wheel bearing in by operating pump. - Insert circlip with needle nose pliers. 1 - Wheel bearing 2 - Thrust tube E-13-1 3 - Piston cylinder HKZ-15 4 - Thrust tube E-10 5 Special nut E-8-214 and pull rod Pressing in wheel hub - Install hub - 1 - and piston cylinder - 2 - with pull rod on wheel bearing. - Install special nut - 4 - and thrust piece - 3 - (with collar toward special nut) on inside. - Press in hub by operating the pump. 1 - Wheel hub 2 - Piston cylinder HKZ-15 3 - Thrust tube E-5 4 - Special nut E-8-214 and pull rod Further installation is in the reverse sequence to removal. Page 4014 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Recall 07V063000: Brake Light Switch Replacement Brake Light Switch: All Technical Service Bulletins Recall 07V063000: Brake Light Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 1999-2006 Volkswagen/GTI 1999-2006 Volkswagen/Jetta 2001-2005 Volkswagen/New Beetle 2001-2007 Volkswagen/R32 2004 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V063000 MFG'S REPORT DATE: February 15, 2007 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 790000 SUMMARY: On certain passenger, wagon, and convertible vehicles equipped with or without cruise control, a brake light switch may malfunction if it was installed incorrectly. CONSEQUENCE: The brake lights could become inoperative, or remain on. Failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before April 27, 2007. Vehicles within the make, model, and model year of this population may be involved in either this recall or 06V-183, but not both. The remedy is the same for each recall. Volkswagen dealers will apply the remedy based on the VIN number of the vehicle. Owners may contact VW at 1-800-822-8987. NOTES: Volkswagen recall No. N4. Customers may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Service and Repair Steering Angle Sensor: Service and Repair Electronic Stability Program (ESP) Following steps are valid only for vehicles with Electronic Stability Program (ESP). Vehicles with ESP are additionally equipped with a Steering angle sensor -G85-. sensor is installed in conjunction with coil connector and slip ring in a housing. Removing - Front wheels and steering wheel must be in straight-ahead position. NOTE: Replacement slip ring is secured as a new part in center position with cable tie Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - Disconnect steering angle sensor connection. - Lift hooks - arrows - carefully and remove steering angle sensor. Installing - Install in reverse order of removal. For vehicles with ESP observe following: When installing, ensure steering angle sensor is correctly seated and is free of stress. - Front wheels and steering wheel must be in straight ahead position. - Remove transportation protection (cable tie) on markings before installing a new steering angle sensor. - Install steering angle sensor, until lugs engage. - Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - A zero compensation must then be performed. Page 5098 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Capacity Specifications Refrigerant Oil: Capacity Specifications A/C Refrigerant Oil Capacity (PAG) Capacity ............................................................................................................................................... .................................... 115 ± 20cc (3.8 ± .68 oz) Note: This is the total A/C system refrigerant oil capacity. Replacement A/C compressors are filled with 135cc (4.5 oz) of refrigerant oil. Page 3889 Fuel Injector: Locations 1 - Evaporative Emissions (EVAP) canister purge regulator valve -N80- (EVAP) */** EVAP system 2 - Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC)* 50 Nm (37 ft lb) - Location: in front of Three Way Catalytic Converter (TWC) 3 - 6-pin harness connector Black - For Heated Oxygen Sensor (HO2S) - G39- before Three Way Catalytic Converter (TWC) and Oxygen Sensor (O2S) heater -Z19- Located at right on underside of vehicle 4 - Oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-* 50 Nm (37 ft lb) - Location: in rear of Three Way Catalytic Converter (TWC) 5 - 4-pin harness connector Black - For oxygen sensor behind Three Way Catalytic Converter (TWC) - G130- and heater for Lambda probe 1 -Z29- Located at right on underside of vehicle 6 - 20 Nm (15 ft lb) Tightening torque influences function of knock sensor 7 - Knock Sensor (KS) 1 -G61- Located on cylinder block, exhaust side Page 5795 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Page 110 2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting of flowcharts. Condition Emissions - Possible MIL ON/Cat Converter DTC's Set Catalytic Converter: All Technical Service Bulletins Emissions - Possible MIL ON/Cat Converter DTC's Set 26 07 06 Sept. 13, 2007 2010271 Supersedes T.B. Group 26 number 07 01 dated Feb. 9, 2007 due to the removal of 2001-2003 2.0L (AVH, AZG, BDC) engines. Vehicle Information Condition Catalytic Converter, Replacement Guidelines Catalyst efficiency faults stored in memory (See DTC table). Technical Background Guidelines for catalytic converter replacement Page 5727 Page 1493 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2625 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 420 Horn Relay: Locations Dual Horn Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Diagrams Shifter A/T: Diagrams 4 Speed Automatic 01M 1. Selector lever handle 2. Sleeve 3. Cover 4. Cover strip 5. Selector lever position display 6. Retainer 7. Frame 8. Bolt, 7 Nm 9. Shim 10. Locking segment 11. Plate 12. Locating spring with roller 13. Selector lever 14. Roller 15. Circlip 16. Selector lever housing 17. Fulcrum pin 18. Bolt, 25 Nm 19. Locking lever 20. Shim 21. Bolt Page 3546 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 5250 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Diagram Information and Instructions Power Seat Relay: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2553 - For engine control module - If necessary, release pressure from cooling system before removing Page 3477 Engine Control Module: Testing and Inspection ECM Voltage Supply Open Circuit, Follow-up Procedure With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply Open Circuit, Correcting All values learned by the Engine Control Module (ECM) and the basic setting values, as well as the readiness code will be erased if the voltage supply is interrupted. Therefore, depending upon the vehicle mileage, it can lead to serious engine running problems. Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test sequence Perform the following operations after voltage supply open circuit: - Switch ignition on for at least 10 seconds. - Switch ignition off. - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. - Check idle speed. Refer to "Fuel Delivery and Air Induction/Idle Speed", See: Fuel Delivery and Air Induction/Idle Speed/Testing and Inspection - Generate readiness code. NOTE: During idling check the Evaporative Emission (EVAP) canister purge regulator valve -N80and the air conditioner are switched off, and the oxygen sensor control learning procedure is initiated. - Perform longer road test until poor driving characteristics are eliminated. Observe the safety precautions when carrying out a road test. During the road test the following operating conditions must be fulfilled: - The coolant temperature must exceed 80 °C When temperature is reached, operating conditions: - Idling - Part throttle - Wide Open Throttle (WOT), and - Overrun must be obtained several times. At Wide Open Throttle (WOT) the speed must exceed 3500 RPM. Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Relay and Fuse Arrangements Horn Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 2012 Crankshaft: Tools and Equipment Counter-hold - AST Tool # T 10172 Counter-hold AST tool# T 10172 Tool is used to turn the crankshaft when checking timing. Also used to counter-hold the oil pump and camshaft chain sprockets. Also applicable to Camshaft of 2.0L BBW gas engines. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2363 ^ Cut wiring at this point to old connector and remove. ^ Fold over and tape brown/white wire of original harness using vinyl tape (see above - Unused wiring, taping back to harness). Fuel pump / fuel gauge sensor overlay harness, connecting to factory harness ^ Connect three wires of overlay harness to their mating factory harness wires using crimp connectors: Part No:111971939B (blue) for blue/red and brown wires Part No:111971941A (light yellow) for violet/black wire Tip: Diesel vehicles, only connect violet/black wire. ^ Install new fuel pump/fuel sender unit. Connect overlay harness to fuel pump / fuel gauge sensor. ^ Install cover for fuel pump/fuel gauge sensor. Fuel pump / fuel gauge sensor overlay harness, routing to instrument cluster ^ Route fuel pump overlay harness, following original harness routing along passenger side floor sill towards "A" pillar and secure using interior vinyl tape. ^ Continue fuel pump overlay harness routing along original harness routing, forward of instrument panel cross member, towards instrument cluster (do not secure with tape at this time). Instrument cluster harness, preparing factory harness ^ Remove insulating tape from factory harness on instrument cluster blue connector back to the point where it joins with the main harness. Tip: Some wires may be looped under tape, be careful not to cut wires while removing tape. Pull any excess (looped) wire in original harness towards blue connector. Instrument cluster wiring, special procedures Page 3900 - Vehicles with engine code AFP, intake manifold lower part, disassembling and assembling, - Vehicles with engine code BDF, fuel distributor, disassembling and assembling. - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Checking Proper Seal - Switch ignition on. - Bridge sockets 2 + 65 of test box with the respective adapter cables. Fuel Pump (FP) must run. - Check proper seal of fuel injectors (visual inspection). With Fuel Pump (FP) running, only 1 to 2 drops per minute should escape from each valve. - Disconnect connection between test box sockets. - Switch ignition off. If fuel loss is greater: - Replace faulty fuel injector: Vehicles with engine code AFP. - Vehicles with engine code BDF. Note the following when installing the fuel injectors: - Replace O-rings on all fuel injectors and wet them slightly with clean motor oil. - Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips. - Position fuel distributor with secured fuel injectors and apply uniform pressure to press it in. - The connectors must audibly engage on valves when attached. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking Injection Quantity - Insert a fuel injector to be tested into a measuring glass of VAG1602 tester for fuel injection quantity. - Using respective adapter cables, connect one terminal of fuel injector to be checked to engine Ground (GND). - Use adapter cable to connect second terminal of fuel injector to VAG1348/3 remote control with VAG1348/3-2 adapter cable. - Connect alligator clip to B+. - Switch ignition on. - Bridge sockets 62 + 65 of test box with the respective adapter cables. Fuel Pump (FP) must run. - Operate VAG1348/3 remote control for 30 seconds. - Repeat test on other fuel injectors. Use new graduated measuring glasses for this. NOTE: Also check spray pattern when checking injection quantity. Spray pattern must be the same for all injectors - After all fuel injectors have been activated, place graduated measuring glasses on a level surface and compare quantity of injected fuel. Specified value: 110 to 130 ml per injector - Disconnect connection between test box sockets. - Switch ignition off. If the measured value of one or more fuel injectors is below or above the indicated specified value: - Replace faulty fuel injector: Vehicles with engine code AFP, item 12, Page 1481 Page 2977 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 5184 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 4874 Clutch Pedal Assembly: Service and Repair Over-Center Spring, Removing and Installing 5 Speed Manual 02J Over-Center Spring, Removing And Installing Special Tools - 3317 Installation clamp Removing Remove driver's side lower dash cover. Refer to Body and Frame. - Tension over-center spring with clutch pedal and fit retaining clamp 3317 from above. Note: Hole (arrow) faces toward clutch pedal. - Bring clutch pedal to rest position and take out over-center spring together with retaining clamp 3317. Installing Pull clutch pedal toward passenger compartment. Page 6520 Axle Nut: Specifications Rear 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace A/T - Torque Converter Installation Precautions Torque Converter: Technical Service Bulletins A/T - Torque Converter Installation Precautions Condition Torque Converter with Needle Bearing, Installing on Transmission with Bushing on Turbine Shaft 32 07 01 Jan.16, 2007, 2002295, Supersedes Technical Bulletin Group 32 number 00-01 dated November 16, 2000 due to inclusion into ElsaWeb. Technical Background Torque converter (with needle bearing) will not install on a transmission with a torque converter bushing installed on the turbine shaft. Latest generation 4 speed automatic transmissions are equipped with a torque converter which contains an integrated needle bearing between the turbine shaft and the torque converter. - Replacement torque converters may be equipped with an integrated needle bearing.This torque converter can be identified by the 4th digit (arrow) of coding (will be a D, H or J). Previous generation 4 speed automatic transmissions were equipped with a bushing between the turbine shaft and the torque converter. Production Solution Not Applicable. Service - Replacement torque converters with integrated needle bearing will not fit previous generation 4 speed automatic transmissions without first removing bushing -A- from the turbine shaft on the transmission. Tools, required Page 1634 - To slacken ribbed belt turn tensioning element in direction of arrow. - Block tensioner with mandrel T10060. - Remove ribbed belt. Ribbed Belt, Removing (all 2.8L 6-cylinder Engine With Power Steering Pump And A/C Compressor) Special tools, testers, measuring instruments and auxiliary items required - Hex bolt M8 X 50 2.8L - 2V NOTE: Engine cover on USA/CDN 2.8L - 2V is similar to European market 2.3L engine illustrated here. Page 1771 Look for one of these symbols on the front of the oil container, and use only oils that display these symbols. Engine oil additives: VOLKSWAGEN does not recommend the use of oil additives. They may adversely affect your New Vehicle Warranty. Engine oil consumption: The rate of the oil consumption depends on the quality and viscosity of oil, the speed at which the engine is operated, the climate, and road conditions as well as amount of dilution and oxidation of the lubricant. Because of these variables, no standard rate of oil consumption can be established, but drivers should expect higher oil consumption at high speeds and when the engine is new. Notes: ^ The engine in your vehicle depends on oil to lubricate and cool all of its moving parts. Therefore the engine oil should be checked regularly and kept at the required level. ^ Make it a habit to have the engine oil level checked with every fuel filling. ^ Lack of sufficient engine oil may lead to severe engine damage. ^ The oil pressure warning light is not an oil level indicator. Always heed all WARNINGS. See: Service Precautions Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 3705 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3791 If the specification "Cat B1 OK" is attained: - Press - button. - Press "0" and "6" for function "end output" and acknowledge by entering "Q" - Turn off ignition. Page 3464 Page 1884 Tires: Specifications Technical data Wheels, tires Part 1 of 2 Wheels, tires Part 2 of 2 Specifications Hose/Line HVAC: Specifications A/C Oil Capacity A/C Oil Capacity Type Production Date Capacity Part numbers are for reference only. Always contact the parts department for the latest part number in formation. Golf/Jetta/GTI From 10/98 135 +/- 15 CC This is the total A/C System Refrigerant oil capacity. Replacement A/C Compressors Supplied by the parts department are filled with 135 cc of refrigerant oil. Refrigerant (PAG) oil R-134a, distribution The total refrigerant oil quantity is distributed in the refrigerant circuit as follows: Compressor approx. 50% When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil into the new pad before installation. Condenser approx. 10% When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new pad before installation. Suction pipe approx. 10% When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new pad before installation. Discharge pipe -When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new pad before installation. Evaporator approx. 20% When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new pad before installation. Receiver drier approx. 10% When replacing refrigerant circuit components, fill an appropriate amount of refrigerant oil (as indicated above) into the new pad before installation. Page 3291 Information Bus: Testing and Inspection Description of On-Board Diagnostics General Information From m.y. 2000 >, instrument clusters are integrated into the "Powertrain" CAN Data Bus network (may also be know as "CAN-Bus" or "Data-Bus"). The Data Bus On Board Diagnostic (OBD) interface -J533- (which is integrated into the instrument cluster) enables data to be exchanged between the various CAN-Bus networks and the Data Link Connector (DLC) "K-wire". The Data Bus On Board Diagnostic (OBD) interface -J533- has specific On Board Diagnostic (OBD) capabilities via address word 19 "Gateway", and must always be coded separately from the instrument cluster. See: Programming and Relearning Connecting VAG 1551 Special tools and equipment - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable Page 4819 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Electrical / Mechanical Repair Wheel Bearing: Electrical / Mechanical Repair Rear Wheel Bearing Press for VW/Audi AST tool# 3420 VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle 2008 suggested user price: 25.92 Assenmacher Specialty Tools 1 800 525 2943 Page 4692 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 5374 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 2772 - Connect multimeter between terminal 2 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 4-pin connector terminal 2 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with 2-pin clutch vacuum vent valve switch - Check wire between test box and 2-pin connector for open circuit according to wiring diagram. Terminal 2 + socket 39 Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch - Check wire between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 39 A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Axle Shafts, Removing and Installing Constant Velocity Joint: Service and Repair Axle Shafts, Removing and Installing Special tools and equipment - 3283 Press tool - VAG 1756 Angle wrench - VW 408A Press tool - VW 402 Press plate - VW401 Press plate - VW 522 Support sleeve - 40-204A Tensioner Removing Ensure wheel bearings are not loaded with 12-point nuts loose. If bearings are loaded by vehicles weight and 12-point nuts are loose wheel bearings will be stressed and their life expectancy reduced. If a vehicle is moved after removing axle shaft, first install outer joint and tighten to 50 Nm (37 ft. lbs.). Lift vehicle to relieve load on front axle. - Loosen 12-point nut. - Disconnect axle shaft from transmission drive flange. - -Mark bolt installation position. Page 4342 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection A/C Pressure Switch F129 A/C Pressure Switch, Electrical Checks Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10.8mm x 1.8mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan V7 (via the coolant fan control module J293 ) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). A/C Pressure Switch, Functional Checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch N25 engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), F129 switches A/C clutch off. - Check cooling fan function. When system pressure increases, F129 causes coolant fan V7 to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condensor is blocked), F129 switches A/C clutch off. Page 1966 Camshaft: Tools and Equipment Camshaft Seal Installer - AST Tool # 3241 Camshaft Seal Installer AST tool# 3241 Used to press in camshaft oil seals. Applicable to: Audi 2.7L & 2.8L v6 engines. - Made in Germany - Contact AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3625 Display Group 034 If the specified values are obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specified values are not obtained: - Carry out road test to free oxygen sensor of possible residues and repeat test. Observe the safety precautions when carrying out a road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: Page 5738 Electronic Brake Control Module: Locations ABS Control Module With Electronic Differential Lock, (EDL) and Anti-Slip Control (ASC) (From August 2000) ABS control module with electronic differential lock, (EDL) and anti-slip control (ASC) (from August 2000) Page 4516 Fluid Pan: Specifications 5 Speed Automatic 09A TIGHTENING SPECIFICATIONS Oil Pan Bolt .......................................................................................................................................... ................................................ 12 Nm (9 ft lb) Page 395 Part 1 Page 39 Section 2 - Radio antenna system diagnosis through radio unit Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit. All models except Touareg and Phaeton: - Select AM or FM. - Press and hold the mix button (black arrow). - Screen will appear that shows "Service Test mode" (white arrow). - Press mix button briefly. ^ Test one indicates current antenna status, i.e. ON or OFF (arrow). - Press mix button briefly again. Page 6347 Diagrams/Electrical Diagrams/Master Diagram Index Diagram 46/4 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Locations Multiple Junction Connector: Locations A Pillar Coupling Station Driver's side The coupling station is located in the front left footwell behind the footwell trim. 1 - Central locking 2 - Electric windows, red 3 - Electric mirror adjustment, blue NOTE: Allocation of the coupling station on the front passenger side A pillar is a mirror image! Page 2028 Piston Ring: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 2301 Spark Plug: Application and ID Engine Code AFP Spark plugs 1) VW Audi 101 000 035 AH Manufacturers Code BKR 5 EKUP Electrode gap max. 0.7 Tightening torque 25 Nm (18 ft lb) 1) Use tool T10029 for disconnecting and connecting the spark plug connector. Remove and install the spark plugs using tool 3122B Page 5348 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 3262 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 2241 Note: Rotate engine only with chain tensioner installed. Otherwise, the camshaft roller chain will skip. - Rotate crankshaft two turns in direction of rotation of engine and check valve timing. With engine installed, cylinder head removed - Using mounting bolt for vibration damper, align crankshaft with mark for TDC cyl. 1 -arrow-. If cylinder 1 is correctly at TDC position, it will be possible to see a slot -arrow- on intermediate shaft sprockets. If the slot is not visible: Turn crankshaft one turn in direction of rotation of engine. Note: If the crankshaft is turned with the cylinder head removed, a second mechanic must guide the camshaft roller chain by hand to prevent blocking. - Set both camshafts to TDC of cyl. 1. - Align camshafts with camshaft guide 3268. - Prepare cylinder head gasket for assembly. Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Page 82 If reception does not return: ^ Problem is located further forward in the system. For problems forward of the antenna system: - Continue with Section 3a. For problems at antenna system: Skip to Section 3b. For problems at antenna systems: Tip: All checks should be done outdoors away from buildings. Section 3a - Problems forward of antenna system - First verify connection at Radio (check for bent or crushed connections and proper fit). If all connections appear ok: - Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception). If reception returns: ^ Problem is located between radio and antenna. - Check connections near center console: If connections are OK: - Check resistance of cable from end to end. ^ If More than .4 ohms: - Replace cable. If reception does not return; - Replace radio unit. Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8) If concern is only AM poor / no reception; Locate AM antenna amplifier. ^ Touareg: located above left side window. ^ Passat W8: Sedan above rear window. ^ Passat Wagon: located on left rear window. - Check for proper connections at amplifier both from diversity box and to glass. If connection issue is at glass or on glass: - Glass must be replaced. If connection problem to amplifier: - Repair connection (replace cable or amplifier). With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 397 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 2838 Display Group 030 Explanation of 3 digit number block in display field 2 Page 5831 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Audio System - Poor Radio Reception Technical Service Bulletin # 9105-01 Date: 050502 Audio System - Poor Radio Reception Group: 91 Number: 05-01 Date: May 2, 2005 Subject: Radio, Reception Diagnosis Model(s): All with Premium V and VI Radio 1998 > 2006 Condition Poor radio reception. Service Procedure For concerns of poor radio reception: - Use the following as a guide for trouble shooting. Tip: This Technical Bulletin is divided into four sections: ^ Section 1: Includes antenna systems by vehicle. ^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics. ^ Section 3: Includes antenna lead diagnosis. ^ Section 4: Antenna cables Tip: ^ Perceived reception issues may be a result of environmental factors. ^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses. ^ Aftermarket window tint may interfere with reception. ^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal). Section 1 - Antenna systems by vehicle Tip: For more detail see Repair Manual Group 91- Communication of the vehicle you are working on. Passat (W8 only) Page 174 Power Seat Control Module: Electrical Diagrams For information regarding diagrams for the Power Seat Control Module, please refer to Memory Positioning Systems / Diagrams. Page 1132 Trunk Lamp Switch: Service and Repair Luggage Compartment Light Switch -F5-, Removing And Installing The luggage compartment light switch is integrated in the rear lid lock and cannot be replaced separately. In case of switch malfunction, replace complete rear lid lock mechanism. Page 3263 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Emissions - Possible MIL ON/Cat Converter DTC's Set Catalytic Converter: All Technical Service Bulletins Emissions - Possible MIL ON/Cat Converter DTC's Set 26 07 06 Sept. 13, 2007 2010271 Supersedes T.B. Group 26 number 07 01 dated Feb. 9, 2007 due to the removal of 2001-2003 2.0L (AVH, AZG, BDC) engines. Vehicle Information Condition Catalytic Converter, Replacement Guidelines Catalyst efficiency faults stored in memory (See DTC table). Technical Background Guidelines for catalytic converter replacement Not Available For Manufacturer's Scan Tool Variable Valve Timing Actuator: Testing and Inspection Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. Page 2643 Display Group 062 - Depress accelerator slowly until Wide Open Throttle (WOT) position and observe angles displayed in display fields 1 and 2. The percentage displayed in display field 1 must rise continuously and evenly. The full tolerance range (3-93%) is not always displayed. The percentage displayed in display field 2 must fall continuously and evenly. The full tolerance range (97-3%) is not always displayed. NOTE: - The display in display field 1 rises and the display in display field 2 falls because the potentiometers (angle sensors) in the throttle valve control modules run in opposite directions. - This means that the voltage of one angle sensor moves toward 5 volts (the more the throttle valve is opened the higher the voltage; percentage increases), while the voltage of angle sensor 2 drops from 5 volts toward 0 volts (the more the throttle valve is opened the lower the voltage; percentage falls). If the specified values are obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 458 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1900 Use grease packet from repair kit Pressing wheel bearing into wheel bearing housing - Install circlip. Note: Make sure the circlip is seated correctly. The opening of the circlip must point downward. Pressing wheel hub into wheel bearing Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed Page 710 Hood Sensor/Switch (For Alarm): Locations Hood Alarm Switch F120 - Hood alarm switch Page 4456 Table of shims for drive pinion and input gear Note: Different tolerances enable the required shim thickness to be measured precisely. - Part number: See Parts Supplier. Recall - ABS Control Unit Replacement Technical Service Bulletin # RECALLWJ Date: 020301 Recall - ABS Control Unit Replacement Recall Circular Code: WJ Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit Dear Volkswagen Dealer: This is to inform you of the initiation of a voluntary safety recall involving some 2001 and 2002 model year Volkswagen Golf, Jetta, GTI and New Beetle vehicles. Problem Description Volkswagen has found that an electronic chip in the control unit could experience an electrical short causing the connector wire insulation to become scorched. Remedial Action Check and replace, where required, ABS control unit. Vehicle Identification Number Ranges The vehicles affected by this recall action are within the following vehicle identification number ranges: Please note that the above VINs represent the lowest and highest serial numbers of affected vehicles. Use of the OTIS campaign inquiry system will allow you to determine whether or not a particular vehicle, within the above VIN ranges, requires the corrective work. Note: Volkswagen will not reimburse under recall any duplicate recall repair work or a repair outside the VIN ranges. Owner Notification Mailing Volkswagen of America, Inc. will mail first class notification letters to all known owners of affected vehicles on or about March 14, 2002. A copy of the owner letter is enclosed for your information. Vehicle Allocation Under separate cover and prior to owner notification, we will provide you a computer printout list containing VINs including owner names and addresses of vehicles located within your dealership's area of responsibility. Note: The above listing will include names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts Information Page 3321 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 4104 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2215 - Remove bolts for timing chain lower tensioner unit light - arrows -. - Remove timing chain lower tensioner unit. Puller - AST Tool # T 40001 Camshaft Gear/Sprocket: Tools and Equipment Puller - AST Tool # T 40001 Puller AST tool# T 40001 Puller used to remove cam sprockets. Comparable to VW # 3032. Applicable: VW 4 cylinder TDI, VW/Audi V6(5V) and Audi V8 (40V). Includes 17mm and 23mm pulling arms. (For 2.0L 4V Direct Injection Engine (BPY)(BPG)(BWT), order additional arms; T 40001-6 and T 40001-7, available separately.) - Used to Remove Cam Sprockets - Comparable to VW # 3032 - Includes 17mm and 23mm pulling arms Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5814 1. Connect cable with positive (+) stamp to inner positive (+) terminal of 1st battery. When doing so, ensure that the other end of the cable (negative) does not make contact with ground or any object. Tighten to 6Nm. 2. Connect the negative (-) terminal of the cable to the inner negative (-) terminal of the 2nd battery. Tighten to 6Nm (53 in. lbs). 3. Connect Midtronics tester positive (+) clamp (red color) to outer positive (+) terminal of 2nd battery. 4. Connect Midtronics tester negative () clamp (black color) to outer negative () terminal of 1st battery. When testing/charging is completed: 1. Remove Midtronics tester negative (-) clamp (black color). 2. Remove Midtronics tester positive (+) clamp (red color). 3. Remove battery cable negative (-) connection at 2nd battery negative (-) terminal. 4. Remove battery cable positive (+) connection at 1st battery positive (+) terminal. Testing/charging 6-Volt Batteries in Vehicle: INC-940 1. Connect Midtronics tester positive (+) clamp (red color) to outer positive (+) terminal of battery. 2. Connect Midtronics tester negative (-) clamp (black color) to outer negative (-) terminal of other battery MCR340V and VAS6161 1. Connect Midtronics tester positive (+) clamp (red color) to outer positive (+) terminal of battery. 2. Connect Midtronics tester negative (-) clamp (black color) to outer negative (-) terminal of other battery. Testing/Charging In or Out of Vehicle: Always verify using DIN rating as shown on battery label. ^ Select AGM for 3.2L engine (located in the trunk, one 6-volt battery on each side of the ski-chute). 380 DIN. Page 4971 Final Drive Fluid: Fluid Type Specifications 02J Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.0 liters Transmission code: DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF Type ..................................................................................................................................................... .......................... G51 SAE 75w-90 (synthetic oil) Transmission codes: DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ..................................................................................................................................................... .......................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Capacity ............................................................................................................................................... ................................................................. 2.3 liters Type .................................................................... ........................................................................................................... G51 SAE 75w-90 (synthetic oil) Page 4185 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 5036 - Carefully pry cover off center console (arrows). - Pull cover to rear off of center console. - Destroy clip (arrow) and pull gear shift knob off with cover. - Remove rubber cover, if fitted. - Remove gear lever housing securing nuts (arrows). Page 4360 Clutch: Service and Repair Reverse Clutch 4 Speed Automatic 01M Reverse gear clutch -K2-, disassembling and assembling Special tools and equipment - VW 401 Thrust plate - VW 460 Removal device - 3267 Assembly ring Note: The clutch should only be disassembled for cleaning or to visually check parts. - When disassembling ensure that the ball valve (arrow) is not damaged. Page 3969 - Remove 4-way connector and feed and return lines from flange -arrows-. NOTE: Press the tabs on the hose couplings together for this. CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. - Plug lines to prevent contamination of fuel system. - Remove union nut with flare nut wrench 3217. - Remove fuel delivery module and sealing ring through fuel tank opening. NOTE: If the delivery module is to be replaced, empty the old delivery module before disposal. Installing - Install in reverse sequence. NOTE: - Do not bend the fuel level sensor while installing. - For assembly, moisten the flange sealing ring with fuel. - Make certain that the fuel hoses fit tightly. - Fasten fuel hoses with spring band clips. - After the flange of the fuel delivery module was installed, check that the feed, return, and vent lines are still clipped onto the fuel tank. Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid Capacity ............................................................................................................................................... .................. 0.7 to 0.9 liter (0.74 to 0.95 quarts) Hydraulic Oil ........................................................................................................................................ ...................................... part number G 002 000 Note: Do not use ATF Page 3362 - Check status of the oxygen sensor control before Three Way Catalytic Converter (TWC) (display field 1). Display Group 030 Explanation of 3 digit number block in display field 1 Page 3272 This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Page 2107 Bu-Ch Page 868 Part 1 Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 4932 Use grease packet from repair kit Pressing wheel bearing into wheel bearing housing - Install circlip. Note: Make sure the circlip is seated correctly. The opening of the circlip must point downward. Pressing wheel hub into wheel bearing Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 6523 6500-17 - 17mm Allen Socket 6500 X-30 - 30mm, 12-Pt. Socket Page 4578 Test Sep 7 - 9 Page 4534 Planetary Gears: Fluid Type Specifications Planetary Gearbox Fluid type Lubricant VW AFT .............................................................................................................................................................. Part Number G 052 990 A2 Page 81 - Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM). - Press mix button briefly again. ^ Screen indicates number of stations broadcasting close to frequency band of selected station. ^ As the number increases for [mp] and (adj], static and signal crossing will increase. To exit service mode: - Depress and hold the mix button or switch radio OFF then back ON Navigation units ^ No internal diagnosis functions. Continue to antenna lead diagnosis. Section 3 - Antenna Lead Diagnosis After initial radio diagnosis using internal service functions, use the following procedures: - Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base. - Check for proper connection. (follow steps for your type of system). - For all systems, locate cable end-point at either diversity box or antenna mast base. - Disconnect cable from either diversity box or antenna mast base. - Carefully ground center wire in cable to chassis. If reception returns: ^ Cable and radio are ok. Page 6392 Ball Joint: Specifications Ball Joint, Lower Torque TIGHTENING SPECIFICATIONS Ball Joint To Control Arm .............................................................................................................................................................. 20 Nm (15 ft. lbs.) Note: Use new bolts. Ball Joint to Wheel Bearing Housing ............................................................................................................................................. 45 Nm (33 ft. lbs.) Page 1284 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 4852 Fig. 1 Centering clutch disc; removing and installing pressure plate Loosen and tighten bolts gradually and diagonally. - Reverse position of retainer 3067 when removing. Note: Pressure plate contact surface and clutch plate must make full contact with flywheel. Tighten bolts diagonally and evenly to prevent damage to the centering holes in the pressure plate housing and the centering pins in the flywheel. Fig. 2 Checking ends of diaphragm spring Wear up to half thickness of the diaphragm spring is permitted. Page 3393 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2317 - Connect contacts on coolant feed pump -V51 - with battery using auxiliary cables from VAG 1594 A. The pump should start. If the pump does not start: - Replace pump -V51-. If the -V51- starts: - Switch ignition off and on. - Connect VAG 1527 B diode test lamp to disconnected attachment plug of coolant feed pump -V51- using auxiliary cables from VAG 1594 A. The LED should illuminate. Note: This test must be conducted within 10 minutes of the time that the ignition was turned off If the LED does not illuminate: Using wiring diagram find and repair open circuit. Page 3599 If the specified value is obtained: - Change to display group 36 as follows: - Press -C- button. - Press buttons -0-, -3- and -6- to input display group number 36 (036) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 36 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by Engine Control Module (ECM). - Check oxygen sensor voltage in display field 1. - Allow engine to run at an increased speed until specified value "B1-P2 OK" appears in display field 4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 2023 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 2622 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1323 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) -G68Removing and Installing VSS -G68Special tools, testers and auxiliary items - Obtain radio code on vehicles with coded radio. - Switch ignition off and disconnect battery ground strap. - Remove battery. - Remove air cleaner. - Install support bar 10-222 A with legs 10-222 A/1 (adapter 10-222 N3 for 6-cyl. engine) and support engine/transmission in position. - Remove bracket for power steering pressure hose. Service and Repair Headlamp Alignment Switch: Service and Repair Headlight Adjuster -E102*- With Instrument Panel Light Dimmer Switch -E20-, Removing And Installing Removing - Protect instrument cluster around cover with adhesive tape if necessary. - Release switch housing from installation frame carefully using a flat point screwdriver. Pull out. - Disconnect electrical connector. Installing - Connect electrical connector. - Insert headlight adjuster in guide on mounting frame and press in. *) Where applicable A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 5608 SUBLETS At -A- Glance For vehicles that, according to your information, cannot be corrected, and one of the codes below best describe the reason, please enter into the system one of the codes indicated, as applicable: Campaign Verification For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding campaign inquiry and verification system; other systems are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as minimize inconvenience to your customers, you are urged to service each vehicle at the scheduled service appointment time, supply a loaner vehicle for the day. Make sure that each vehicle is returned to the customer washed and cleaned inside. In the event the customer waits during the service, do not let them wait longer than specified for the recall repair service in the owner notification letter. Please make every effort to reduce inconvenience to customers. Service Help Dealer Personnel Information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Thank you for your cooperation. Overview This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Page 657 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 2719 Engine Control Module: Service and Repair Replacement ECM, Adaptation (Function 10) Replacement Engine Control Module (ECM), Adaptation (function 10) NOTE: - The engine control module is adapted to the immobilizer control module in the instrument cluster. When changing a component it must be readapted. - If an authorized ignition key is not available but the secret number is, new ignition keys must be manufactured and adapted. - The adapting can be interrupted with the "C" button of VAG 1551 Requirements Authorized ignition key available. - Insert old (authorized) key in ignition lock. - Connect VAG 1551, select operating mode 1, "Rapid data transfer". Switch ignition on and enter address word 17, "Instrument cluster". After control module identification has been displayed: Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select function 10, "Adaptation". Indicated on display Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display Adaptation Enter channel number XX - Press button -0- twice to select "Channel O". - Press -Q- button to confirm input. Indicated on display Adaptation Q Erase learned value? - Confirm entry with -Q- button. Indicated on display Adaptation -> Learned values are erased - Press -> button. Indicated on display Rapid data transfer HELP Page 3022 Spark Plug: Tools and Equipment Plug Connector Remover - AST Tool # H 1849-6 Plug Connector Remover AST tool# H 1849-6 Used for spark plug boot removal. Applicable to VW VR6 engine and is comparable to VW tool # T10029. - For the R and R of Spark Plug Connectors - Applicable to VW Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3781 If after repairing other fault codes and setting readiness code, and any fault codes in the table return: Replace catalyst(s) as necessary, using applicable SRTs. If software updates do not apply, and only one or more of the following fault codes (DTCs) are present (see table): If DTC text indicates bank 2, bank 3, bank 4: Verify catalyst location before replacement, see Service Manual repair group 26. Use applicable SRTs. For technical assistance, select the "Technical Assistance" tab in ElsaWeb and follow the instructions to obtain a 6 digit pin. Tip: Before repairing vehicle or erasing fault codes (DTCs) remember to make print-outs including freeze-frame data as required and attach to the repair order. If catalytic converter is on parts submission, attach copies of all supporting documentation (including printouts) required when sending parts to Warranty Test Center. Page 2164 - If replaced, perform engine control module adaptation. - No cable disc for accelerator cable as this is an electronic accelerator system. - Harness connector contacts gold plated. - Heated by coolant. 11 - Ground Wire 12 - Vacuum Positioning Element. For Intake Manifold Change - Over Valve -N156-. - Check. 13 - To Intake Manifold Change - Over Valve -N156-. 14 - Bracket. For engine cover. 15 - Positioning Lever. For change-over barrel. - Check securely seated. Page 6109 S164 - Fuse -3- (30) in fuse bracket/battery S176 - Fuse -4- (30) In Fuse Bracket/Battery S176 - Fuse -4- (30) in fuse bracket/battery S177 - Fuse -5- (30) In Fuse Bracket/Battery Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity 2.8L 174hp AFP Capacity ............................................................................................................................................... ............................................... 5.5 liters (5.8 quarts) Page 5813 ^ Eos 3.2L AGM batteries shown are connected in series. Tip: DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions: ^ Battery was removed for a separate repair prior to performing battery test. ^ Over the counter (after market) parts. Testing/Charging 6-Volt Batteries Out of Vehicle: If batteries have been removed from vehicle, never attempt to test/charge one 6-volt battery; as stated above. Treat batteries as a 12-volt system. ^ Connect cable (Part No: 1Q0971226) to inner battery terminals. ^ Connect battery tester. Tip: Cable has (+) and (-) stamps on each terminal. Positive (+) terminal is a larger diameter than Negative (-) terminal. DO NOT attempt to force the wrong terminal of harness onto a battery terminal if it does not fit. Page 2851 Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control Before TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (Before Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair contacts 3 and 4 in the oxygen sensors harness connectors. Special tools and equipment - VAG1551/VAG1552 with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - Min. coolant temp. 85 °C See display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -3- and -0- to input display group number 30 and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 Page 3818 - To upper intake manifold, item -4- 8 - Leak detection pump (V144) Checking 9 - Air filter for leak detection pump 10 - Intake hose Make sure tight fit tight fit 11 - Mounting plate Clipped onto the charcoal canister 12 - 10 Nm 13 - Activated charcoal canister In the rear right wheel housing underneath the liner - Fastened to the body 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 4768 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 265 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 2454 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 5711 Page 2991 - Check Fuel Pump (FP) current draw as follows: - Reconnect all disconnected fuel lines. - Connect multimeter with electrical current probe to wire of 4-pin connector (terminal 1 arrow) from wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max: 8 amperes NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3409 - Use wiring diagram to check cables between test box and connector for any broken connections. Contact 1 + cavity 72 - Contact 2 + cavity 73 - Contact 3 + cavity 36 - Contact 4 + jack 35 - Contact 5 + jack 33 - Contact 6 + jack 34 - Line resistance: max. 1.5 Ohms - Also check cables for a short circuit to battery positive terminal or to ground. - Also check cables for short circuits between each other. If no problems can be found in the cables: - Replace throttle position sensor (G79), item -4-. Page 5594 Use only Volkswagen approved brake fluid CAUTION! BRAKE FLUID IS POISONOUS. BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. ^ Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper ^ With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw ^ Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle ^ Ensure that brake fluid in the reservoir is at the correct level ^ Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 1601 Clay St., Detroit, MI 48211 ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL! Page 3293 - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. - The -> button is used for advancing through the program sequence. - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Connecting VAS 5051 Special tools and equipment Page 5380 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 1264 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation Page 3521 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 1528 This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Page 3482 - The respective fuses of Motronic Engine Control Module (ECM) - J220- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Generator (GEN) must be OK, checking. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. Test sequence - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Checking voltage supply terminal 30 - Measure voltage supply between sockets 1 + 62 and 2 + 62 of test box. Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram: - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking voltage supply terminal 15 - Measure voltage supply between sockets 1 + 3 and 2 + 3 of test box. - Switch ignition on. - Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 6393 Ball Joint: Testing and Inspection Axial play, checking - Pull ball joint down and press up again. Radial play, checking - Press lower part of wheel out and in. NOTE: ^ There must be no visual play for both tests. ^ Observe ball joint during checks. ^ Take into account wheel bearing and/or upper strut mount movement. ^ Check rubber boot for damage, replace ball joint if necessary Service and Repair Cylinder Head Gasket: Service and Repair For further information regarding this component please refer to Cylinder Head Assembly; Service and Repair. Page 3757 Air Injection Pump: Testing and Inspection With Generic Scan Tool Secondary Air Injection (AIR) Pump Motor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Secondary Air Injection (AIR) Pump Motor -V101- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Secondary Air Injection (AIR) Pump Relay -J299- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Ignition switched off. Test sequence - Remove front noise insulation. Vehicles with engine code AFP - Disconnect 2-pin connector from motor for secondary air pump (arrow). Vehicles with engine code BDF Page 4573 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Transmission Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant 40 - Multi-Function TR Switch -F125- (pin 2) Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (Automatic transmission) Page 4821 Page 5398 Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing Note: Tire and wheel removal is not necessary Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening Note: The label showing supplier code is upside down in vehicle ^ If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C ^ If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation ^ Obtain radio code and record radio preset stations ^ Turn Ignition Switch to "OFF" position ^ Open hood and place fender cover in position ^ Disconnect the ground cable (GDN) from the negative (-) battery terminal <-- Disconnect electrical connector -1- from mass air flow sensor -2<-- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) Page 4394 Control Module: Locations J217 - Transmission Control Module (TCM) Page 5406 Page 2543 Thermostat: Locations Thermostat Location - The thermostat is mounted in the housing and located on the rear of the cylinder head. Components 1. Coolant pipe - Secured to exhaust gas manifold together with heat shield. 2. 10 Nm 3. To heat exchanger 4. From heat exchanger 5. Throttle Valve Control Module -J338- Heated by coolant. Page 284 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 4074 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 5397 Special Tools: Section A Section A - Check ABS Control Module Part Number ^ Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column ^ Switch ignition to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics." ^ Read control module part number and code located in the upper right corner of the screen ^ If ABS control unit part number is 1C0 907 379 C, press <-- button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B ^ If ABS control unit part number is not 1C0 907 379 C no further work is required, press <-- button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code ^ Drive vehicle into hoist area ^ Raise vehicle on hoist Specifications Valve Clearance: Specifications Valve clearance Less than 0.2 mm more than 0.1 mm Page 3315 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Ignition Page 1054 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 2360 ^ Remove pin (brown/white wire) from cavity 9 (black arrow) of this connector. ^ Cut connector from brown/white wire removed from cavity 9, then, fold loose wire end back to harness and secure with vinyl tape (see above - Unused wiring, taping back to harness). ^ Insert terminal / wire (5 cm) previously removed (see above - Engine overlay harness, preparation) from engine overlay harness into cavity 9. ^ Reattach single wire portion of engine overlay harness (previously removed) to pin 9 of (10 or 14 pin) connector using wire splice Part No: 111971941A (shorten wire to achieve correct length). ^ Reconnect connector. ^ Continue harness routing down cable channel. then loop behind channel and route to bulkhead. ^ Reinstall cable channel cover. ^ Push guide tube through main harness (arrow) into vehicle interior at bulkhead. From inside vehicle, behind relay panel: ^ Pull guide tube with overlay harness inside vehicle. ^ Continue routing two wire portion of engine overlay harness along main harness towards instrument cluster following original harness route along cross member (DO NOT secure with tape at this time). ^ Remove guide tube from harness. Page 5027 - Turn right-angled piece -A- back to original position (direction of arrow). - The selector shaft must now be able to be moved (in direction of arrow). - Pull pin T10027 out of holes -A- and -B-. - Clip boot into frame. Functional check - The gear shift lever must rest in the 3rd/4th gear gate with the transmission in neutral. - Operate clutch. - Select all gears several times. Pay particular attention to operation of reverse gear lock. Should a gear fail to engage smoothly after repeated selection, the selector shaft play (lift) should be checked as follows: Engage 1st gear. - Press gear lever to left onto stop and release while observing selector shaft in transmission (2nd mechanic). Page 5484 Brake Pedal Assy: Service and Repair Brake Pedal to Brake Booster, Disconnecting and Connecting Special tools and equipment required ^ T 10006 Release tool Additional information ^ Remove trim below instrument panel. ^ Remove screws -1-. ^ Remove cover -A-. ^ Remove connecting plate between clutch and brake pedals (arrows) on vehicles with a manual transmission. ^ Remove brake light switch -1-. Page 3666 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 552 Engine Control Module: Testing and Inspection ECM Voltage Supply Open Circuit, Follow-up Procedure With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply Open Circuit, Correcting All values learned by the Engine Control Module (ECM) and the basic setting values, as well as the readiness code will be erased if the voltage supply is interrupted. Therefore, depending upon the vehicle mileage, it can lead to serious engine running problems. Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test sequence Perform the following operations after voltage supply open circuit: - Switch ignition on for at least 10 seconds. - Switch ignition off. - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. - Check idle speed. Refer to "Fuel Delivery and Air Induction/Idle Speed", See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Idle Speed/Testing and Inspection - Generate readiness code. NOTE: During idling check the Evaporative Emission (EVAP) canister purge regulator valve -N80and the air conditioner are switched off, and the oxygen sensor control learning procedure is initiated. - Perform longer road test until poor driving characteristics are eliminated. Observe the safety precautions when carrying out a road test. During the road test the following operating conditions must be fulfilled: - The coolant temperature must exceed 80 °C When temperature is reached, operating conditions: - Idling - Part throttle - Wide Open Throttle (WOT), and - Overrun must be obtained several times. At Wide Open Throttle (WOT) the speed must exceed 3500 RPM. Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Service and Repair Evaporative Emission Control Canister: Service and Repair Evaporative Emissions System Components, Repairing 1 - O-Ring Replace if damaged 2 - Vent line Black - Make sure tight fit - From the switch valve on the fuel tank, item -10- Press release tabs on the connecting piece to remove from flange 3 - Vent line White - Make sure tight fit - From the pressure retention valve on the fuel tank, item -12- Press release tabs on the connecting piece to remove from flange 4 - Retaining screw 5 - Discharge hose Make sure tight fit 6 - Connector Black, 3-way 7 - Vacuum line Page 1020 ^ Disconnect wiring harness connector -1- from brake light switch -2-. ^ Remove brake light switch by turning (counterclockwise) and pulling switch out of retainer. Obtain the new brake light switch. Note: DO NOT press new brake switch plunger prior to installation. Pre adjustment of plunger will result in inoperative brake lights or brake lights staying on all the time ^ Grasp brake light switch and brake light switch plunger (black arrow). ^ ^Carefully pull the plunger out to full length. ^ Apply a light coat of lubricant Part No. G052142A2 (obtained locally and considered shop supply) to the end of the plunger (black arrow). Note: Lubricant must be applied to prevent premature wear of brake light switch plunger. Brake light switch can only be installed once! Installing switch a second time may result in an inoperable switch. Leave brake pedal in resting position. DO NOT press or hold up brake pedal during brake light switch installation. ^ Carefully insert brake light switch -2- fully into mounting hole (switch will only fit in the access hole one way), pressing the plunger against the brake pedal to adjust position. Tip: A ratcheting sound indicates the brake light switch plunger is being set in position. Underhood Views Battery: Locations Underhood Views Underhood View: Always heed all WARNINGS: See: Maintenance/Service Precautions Always exercise extreme caution when working under the engine hood. Gasoline Engine 174 Hp (2.8L) 1 - Windshield washer container 2 - Coolant expansion tank 3 - Engine oil dipstick 4 - Engine oil filler cap 5 - Brake fluid reservoir 6 - Vehicle battery (protected by a cover} Page 4568 Test Step 7 - 15 Page 5975 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 264 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Service and Repair Brake Bleeding: Service and Repair Brake system, bleeding Vehicles with ABS and ABS/EDL When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled using the VAG 1551 scan tool in function 04, "basic setting". WARNING! Do not exceed a filling pressure of 1 bar (14.5 psi) when filling with brake fluid using pressure bleeder US1116. The brake system will not be completely bled if excessive pressure is used. Notes: ^ Bleeding the brake system on vehicles with ABS is the same as for vehicles with conventional braking systems with the exception of using function 04 to bleed systems that have been completely empty. ^ Brake fluid absorbs moisture from the air and must therefore be replaced every two years. Use only new, unused and approved brake fluid that complies with MVSS 116 DOT4. Notes: ^ Brake fluid is poisonous. Also due to its corrosive effect brake fluid must not come into contact with paintwork. ^ Brake fluid must always be stored in airtight containers. ^ Do not use silicone-based brake fluid (DOT 5). Even the smallest trace can cause severe corrosion in the brake system. ^ Rinse off brake fluid spillages using plenty of water. Brake system, bleeding using US1116 pressure bleeder Special tools and equipment required ^ US 1116 brake bleeder ^ Connect brake filling and bleeding unit. ^ Open bleeder valves in specified sequence and bleed brake calipers. Bleeding sequence 1 Right rear caliper 2 Left rear caliper 3 Right front caliper 4 Left front caliper Vehicles with ABS or ABS/EDL ^ Test drive vehicle and perform at least one brake application sufficient to engage ABS regulation. Brake system, bleeding without pressure bleeder ^ Build-up brake pressure in brake system by pumping brake pedal. ^ Connect hose from bleeder bottle to brake bleeder valve at each wheel in turn. ^ Open bleeder valve. ^ Hold brake pedal down, close bleed screw. Note: The brake fluid level in the reservoir must not fall below the MIN mark during bleeding. ^ Release brake pedal. ^ Repeat operation until brake fluid flows without air bubbles. Page 3480 If the specified value is not obtained: - Remove wiper arms and plenum chamber cover. Page 5881 - Reinstall cover -1 - with screws -arrows-. CAUTION! If battery is not secured properly, the following will result: - Shortened battery service life due to vibration damage. - Battery cell and plate damage. - Electrolyte leakage due to battery case damage. - Poor collision safety. Page 2746 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2413 Radiator Cooling Fan Control Module: Connector Views Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 1999) Page 5822 Page 5341 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 5286 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 2496 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1503 Heated Glass Element Switch: Electrical Diagrams For information regarding diagrams for the Rear Window Defogger Switch, please refer to the Power and Ground Distribution / Standard Equipment Diagrams. Page 2754 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Page 5099 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Page 646 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Page 1050 Brake Light Switch: Locations F - Brake light switch Page 681 Service and Repair Parking Brake Lever: Service and Repair 1 Parking brake lever ^ Before removing take out center console 2 Circlip 3 Parking brake lever trim ^ Pull off toward front ^ Use a screwdriver to release strap under lever 4 Hex nut, 25 Nm (18 ft. lbs.) 5 Adapter ^ For vehicles with center armrest 6 Pull rod 7 Compensator 8 Adjusting nut ^ Adjusting parking brake 9 Fulcrum pin ^ Holds pull rod -6- in parking brake 10 Parking brake cables ^ Removing and installing 11 Parking brake warning light switch Page 631 Test Step 5 - 6 Page 4777 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3465 Page 4438 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 2217 Special tools, equipment, test and inspection devices; required accessories - 3268 Camshaft ruler - 3406 Counter-hold - T10029 Spark plug connector tool - VAG 1331 torque wrench (5 - 50 Nm) - VAG 1332 torque wrench (40 - 200 Nm) Procedure With engine removed Install roller chain and chain tensioner with tension bar: Page 3539 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 133 Door Module: Locations Door Control Module, Driver and Passenger Side Door control module, driver- and passenger side Door Control Module, Rear Left and Rear Right Engine Controls - MIL ON/DTC P0134 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0134 Set Group: 01 Number: 04-20 Date: Oct 27, 2004 Subject: Malfunction Indicator Light (MIL) ON with DTC P0134 Stored in DTC Memory Model(s): Golf / Jetta with 2.8L VR6-2V 1999 --> 2002 (Eng. code AFP) Condition Customer states Malfunction indicator light is ON in the instrument cluster. Concern may be accompanied by Diagnostic Trouble Code (DTC) P0134. Service - Verify customer concern. See Workflow Overview for Service Procedures incorporated into this Technical Bulletin. CAUTION! Part numbers listed in this T.B. are for reference only. Always check with your Parts Dept. for the latest parts information. Note: Procedure must also be performed on applicable vehicles in Dealer inventory. Procedure: Update - Programming (Flashing) CAUTION! When performing the reflash procedure, ALL DTCs for all systems are erased. Page 3026 Compression Check: Testing and Inspection Compression pressure, checking Special tools, equipment, test and inspection devices; required accessories 3122 B Spark plug removal tool - T10029 Spark plug connector tool - VAG 1331 Torque wrench (5-50 Nm) - VAG 1763 Compression tester Test condition - Engine oil temperature must be at least 30°C. - Battery voltage must be at least 11.5 V. Test procedure - Disconnect connector from heating resistor (N79) and remove intake hose between upper half of air filter and throttle control unit (J338) together with crankcase purge valve. - Use assembly tool T10029 to remove spark plug connector and ignition lines. - Remove engine cover. - Remove spark plugs with spark plug tool 3122 B. Page 4701 Page 4166 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 4696 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4734 Shift Cable: Adjustments 5 Speed Automatic 09A Selector lever cable, checking and adjusting Checking - Shift selector lever into "P" position. - Pull selector lever cable -1- upward off lever/selector shaft -4- and position so that end is free to move. Note: Do not bend or kink the selector lever cable. - Shift selector lever from "P" to "2". - Check front protective sleeve on selector lever cable for damage, if necessary replace cable. - Shift selector lever into "P" position. Selector lever mechanism and selector lever cable must move freely, if necessary replace selector lever cable, or service selector lever mechanism. - Press selector lever cable onto lever/selector shaft using a pair of pliers. - Replace circlip -3- if it has been removed. Adjusting - Shift selector lever into "P" position. - Loosen bolt -2- at front ball socket of selector lever cable -1-. - Bring selector shaft lever in position "P" on transmission. Locking lever must engage in park lock wheel, both front wheels are blocked (cannot be turned together in a direction). - Tighten bolt -2- (13 Nm). - Check gear change mechanism. Page 4000 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 6115 Relay Arrangements On The Relay Panel Front Axle Nut: Specifications Front Vehicles with 12-point nut Tighten 12-point nut to 200 Nm (147.5 ft lb) and then loosen 1/2 turn. Turn hub 180°. Tighten 12 point nut to 50 Nm (37 ft lb) plus an additional 60° turn. Vehicles with hex bolt Tighten hex bolt to 250 Nm (184.4 ft lb) and an additional 90° turn and then loosen 1/2 turn. Turn hub 180°. Then finally tighten to 250 Nm (184.4 ft lb) plus additional 90° turn. To tighten 12-point nut/hex bolt we recommend the angle measuring wrench VAG 1756. NOTE: If an angle measuring wrench is not available, then tighten 12-point nut using following method: - Lower vehicle until the wheels touch ground. - Tighten 12-point nut to 200 Nm (148 ft lb) and then loosen 1/2 turn (180°). - Tighten 12-point nut to 50 Nm (37 ft lb). Page 5386 ABS Control Module W/Electronic Differential Lock And Anti-slip Control (ASC) From August 2000 Control Modules - Connector Pin-out Page 5819 Battery: Technical Service Bulletins Electrical - Diagnosis for Excessive Static Current Draw 27 08 04 August 28, 2008 2016076, Supersedes Technical Bulletin Group 27 number 07-11 dated Oct. 2, 2007 due removal of Routan applicability. Vehicle Information Condition Battery, Discharged, Diagnosis for Excessive Static Current Draw Technical Background One or more of the following symptoms is possible. ^ Discharged battery ^ Engine does not start because of low battery voltage ^ Voltage display in the combination instrument displays too low "Low battery" fault codes in various control modules. Production Solution Battery/Current draw procedure introduced in VAS 5051A/B scan tool with the release of software version 11.78.00. Service Check the fault memory. ^ Compare control units on the fault memory print-out with vehicle equipment (PR numbers). Are all necessary control units listed on the print-out? Any control units not listed may be faulty and could be indications for the further fault finding. ^ Check which non-genuine parts are installed, e.g. tow bar, animal protection, radio, DVD, etc. If an increased closed-circuit current is found, check these components first. Step 1: Verify Battery Condition 1. Connect Midtronics INC-940 to battery. Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 5834 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6499 Special tools, testers and auxiliary items required ^ Thrust pad 40 - 105 ^ Press tool 3283 ^ Collar for wheel bearing inner race 3423 ^ Engine and transmission jack V A.G 1333 A with universal transmission mount V.A.G. 1359/2 ^ - 2 - Puller Kukko 18/0 Special tools, testers and auxiliary items required ^ Foot pump with high pressure hose V.A.G. 1389A/1 If there is a hand pump V.A.G. 1389/1 available in the dealership it can be converted to a foot pump. To do this use the conversion kit V.A.G. 1389/4. Page 3916 29 - 6-pin Harness Connector. - Black. - For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) heater - Z19 -. - Located at right on underside of vehicle. Page 2225 - Install cylinder head - Push sliding rail onto bearing bolt. Insert short mounting screw with "D6" locking compound and tighten both bolts to 20 Nm. - Place camshaft roller chain on intermediate shaft (note direction of travel). - Mount camshaft sprocket and roller chain on camshaft for cylinder bank 1, 3, and 5 (long camshaft) and counter tighten by hand. - Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and tighten by hand. Note: Coat contact surfaces of the bolt heads with oil when installing. - Remove camshaft guide 3268. - Tighten mounting bolts for camshaft sprockets to 100 Nm. Note: Hold camshaft - arrow - only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten mounting bolt to 10 Nm. - Replace oil seal for sealing flange. - Prepare cylinder head gasket for assembly. - Coat sealing surface of cover piece with AMV 188 001 02. - Coat O-ring for oil passage seal and insert in cover piece. Page 5461 Wheel Speed Sensor: Locations Left Front ABS Wheel Speed Sensor G47 - Left Front ABS Wheel Speed Sensor Page 2191 Camshaft Gear/Sprocket: Tools and Equipment Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) - AST Tool # T 40001-6 Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) AST tool# T 40001-6 Puller Claw - Accessory Arm (25mm spread). Used in conjunction with T 40001 Puller and T 40001-7 Arm. (Not part of the T 40001 kit; order separately.) Applicable to: VW/Audi; 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT); Used to remove Camshaft Gear/Wheel. - Made in Germany - Contact AST for pricing - Applicable; VW/Audi 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT) - Thin fingers on end of Claw to fit into the tight area behind the Cam Wheel Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: Page 1539 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2109 Fu-Lo Page 92 - Antenna Selection Control Module -J515- (Diversity box) -3-: ^ Location Wagon; behind left luggage compartment side trim, below rear side window. ^ Location, Sedan: under rear parcel shelf. Antennas: All models use four antennas -1-, -8-. ^ Location Wagon: Integrated with rear side windows. ^ Location Sedan: Integrated with rear window. Antenna amplifiers: All models use four antenna amplifiers -2-. ^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows. ^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim. Touareg Page 6121 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5471 ^ Secure wheel speed sensor wire (arrows). Note: Do not twist wires in the wheel well. ^ Cut 2-pin connector at new speed sensor wire (if installed) using stripping pliers from repair kit. ^ Strip 15 mm (5/8 inch) insulation off wire end and fold over stripped wire. ^ Connect wheel speed sensor wire using correct connector from wiring repair kit VAS 1978. Page 929 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2591 If the specification "Cat B1 OK" is attained: - Press - button. - Press "0" and "6" for function "end output" and acknowledge by entering "Q" - Turn off ignition. Page 2704 - Perform resistance measurement again between test box sockets 77 + 79: Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Terminal Resistance For CAN-Bus, Checking Function The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm Page 6024 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 6449 Use grease packet from repair kit Pressing wheel bearing into wheel bearing housing - Install circlip. Note: Make sure the circlip is seated correctly. The opening of the circlip must point downward. Pressing wheel hub into wheel bearing Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed Sensor For Transverse Acceleration (Vehicles With ESP) Lateral Accelerometer: Locations Sensor For Transverse Acceleration (Vehicles With ESP) G200 - Sensor for transverse acceleration (vehicles with ESP) Page 1309 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 5072 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 165 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 316 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 2071 Ribbed Belt: Service and Repair Serpentine Belt Ribbed belt routing NOTE: Before removing ribbed belt, mark direction of rotation. When installing the belt ensure it is correctly seated in the pulley. 1 - Ribbed belt tensioner 2 - Generator pulley 3 - Compressor pulley 4 - Power steering pump pulley 5 - Crankshaft pulley/vibration dampener 6 - Water pump pulley With Manufacturer's Scan Tool Engine Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Engine Speed (RPM) Sensor -G28-, Checking The engine speed (RPM) sensor -G28- is a speed and reference mark sensor. The engine will not start if there is no speed signal. If the speed signal fails when the engine is running, it will cause the engine to stall immediately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test sequence - Disconnect grey 3-pin harness connector (arrow) from engine speed sensor. - Measure sensor resistance between terminals 2 + 3 of harness connector to sensor. Specified value: 480-1000 ohms - Check sensor for short between terminals 1 + 2 as well as -1- + -3-. Specified value: infinity ohms If the specified values are not obtained: - Replace engine speed (RPM) sensor -G28-, item 25. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 4341 Part 2 Page 298 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED 4 Speed Automatic 01M, Locking Cable, Adjusting Shift Interlock Cable: Adjustments 4 Speed Automatic 01M, Locking Cable, Adjusting Locking cable, adjusting WARNING: The description below for the adjustment of the locking cable must be strictly adhered to. Adjustment requirements: Locking cable correctly fitted - Center console removed. - Selector lever in position "P" - Ignition key withdrawn. Adjustment sequence: - Slide sliding sleeve -1- forward. - Release clip -2- by pressing upward. - Pull off connector -4-. - Remove sleeve -5- upward. - Release selector lever housing cover at retaining tabs -6- (Qty. 4) by hand and lift off. - Carefully pry off four corners of frame -7- and remove. Page 3129 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 931 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3578 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 341 Radiator Cooling Fan Control Module: Electrical Diagrams For information regarding diagrams for the Coolant Fan Control, please refer to the Heating and Air Conditioning System Diagrams 38\3 to 38\5 and 39\7 to 39\8 See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Air Conditioning - Manual, From May 1999/Diagram 38\3 (Track 15-28) See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Climatronic, From May 1999/Diagram 39/7 Also Shown in Coolant System Diagrams for Vehicles With Heater Only See: Diagrams/Electrical Diagrams/Radiator Cooling Fan/System Diagram/Coolant Fans, From May 1999/Diagram 37\2 (Track 1-14) Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 132 Door Module: Locations Door Control Module, Passenger Side J387 - Door control module, passenger side Page 563 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Coding Engine Control Module (ECM), Coding NOTE: - A 5-character code must always be displayed during the control module identification. - The control module must be recorded if the vehicle relevant coding is not displayed or the control module has been replaced. Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -7- to select "Code Control Module" function 07 and press -Q- button to confirm input. Indicated on display Code Control Module Enter code number XXXXX (32000) - Enter relevant code number for vehicle and press -Q- button to confirm input. Coding variants: Coding Vehicle 00031 Manual Transmission 00033 Automatic Transmission The control module identification and coding are indicated on the display, (example) 0219060186 MOTRONIC ME7.1G V06 -> Coding 00000 WSC 00000 Indicated on display when a non-authorized code number has been entered Function is unknown or -> cannot be carried out at the moment. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. NOTE: The code entered and shown on the display will not be used by the Motronic control module until the ignition has been switched off once. An incorrect coding leads to: - Engine running malfunctions (rough gear changes, load change jerks, etc.). - Increased fuel consumption. - Increased exhaust gas emissions. - Malfunctions stored in DTC memory which are not actually present. - Functions will not be performed (Oxygen Sensor (O2S) control, activation of the EVAP system, etc.). - On front wheel drive vehicles the traction control will not function (TC warning lamp comes on). Diagram Information and Instructions After-Run Coolant Pump: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1760 Fu-Lo Specifications Spark Plug: Specifications Spark Plugs AFP VW Part Number ................................................................................................................................. ................................................. 101 000 035 AH Manufacturer Designation (NGK) ............................................................................................................................................................ BKR 5 EKUP Spark Plug Gap ............................................................................................................. ....................................................................................... 0.7 mm Tightening Torque .......................... ...................................................................................................................................................... 25Nm (18 ft. lb.) Page 2451 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 2361 ^ Seal engine harness grommet in engine compartment (where overlay harness was pulled through) with Butyl sealer. Engine overlay harness, routing to coolant bottle ^ Engine overlay harness must be routed following factory harness behind fuel and evaporative emission tubes and into plastic clip (arrow) that secures factory harness. ^ Continue overlay harness routing along original harness back to coolant reservoir. ^ Install new coolant reservoir. ^ Cut old coolant reservoir connector from original harness, fold and tape wires back to harness using vinyl tape (see above - Unused wiring, taping back to harness). ^ Connect overlay harness connector to new coolant reservoir. ^ Locate connector to washer level sensor and cut from factory harness (tape brown/white wire back to harness (see above - Unused wiring, taping back to harness). ^ Splice purple/white wire from overlay harness to factory harness using yellow splice (seal using hot air blower). Vehicles with Climatronic ^ Disconnect and inspect ambient temperature sensor -G17- connector for coolant contamination (located behind bumper left side). If coolant contamination is NOT found: ^ Cut brown/white wire from ambient temperature sensor harness approx. 5 cm (2 in.) away from connector. Using light yellow splice connectors Part No: 111971941A: ^ Adding wire as necessary to reach sensor, splice brown/white wire from overlay harness to ambient sensor connector wire (follow and tape to existing harness as necessary) (use Part No: 000979981 for additional wire). If coolant contamination is found: ^ Install new ambient temperature sensor. Locations Power Door Lock Control Module: Locations Comfort System and Central Locking System, Assembly Overview 1 - Coupling station Installation position: Lower A-pillar, covered by trim in footwell - Remove A-pillar lower trim to remove 2 - Door control module, FR For comfort system only - Integrated into window motor - Removing: Remove door trim - Remove window motor. 3 - Door lock, FR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 4 - Coupling station Installation position: B-pillar Page 5494 ^ Press piston into brake caliper housing using piston resetting tool. The protective seal outer sealing lip must slip into the piston groove. Page 1991 Connecting Rod: Specifications Connecting rod cover Bolts 30 Nm plus 1/4 turn Page 2407 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 293 Page 1763 Pr-Sh Page 5883 Battery: Service and Repair Battery, Removing and Installing Removing - Switch ignition off. - Open cover -1- for battery case and unhook. - First disconnect negative GND terminal (arrow) from battery negative (-) pole. - Disconnect positive B+ terminal from battery positive (+) pole. CAUTION: Never disconnect or connect the positive B+ terminal from battery while the negative GND terminal is connected Danger of short circuit! - Flip fuse holder -3- upward. - Remove fastening bolt -1- from battery case and remove battery case together with heat protection jacket. - Remove (M8 X 25) hex bolt -3-. - Remove clamping bracket. - Remove battery. Installing To guarantee the battery seats securely only install batteries with a 10.5 mm battery foot strip and adhere to the following procedures: Page 1474 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 2973 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- A/C Refrigerant Low Pressure Switch F73 Low Pressure Sensor / Switch: Description and Operation A/C Refrigerant Low Pressure Switch F73 A/C Refrigerant Low Pressure Switch F73 Function: Switches off A/C compressor when pressure drops in the refrigerant circuit (approx. 2 bar). Note: A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Page 3513 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Page 3528 If the display does not change: - Disconnect 2-pin harness connector from clutch vacuum vent valve switch -F36-. - Measure resistance between switch terminals -1- and -2-. - Specified value without clutch depressed: max. 1.5 ohms - Specified value with clutch depressed: max. infinity ohms If the specified values are not obtained: - Replace clutch vacuum vent valve switch -F36-. NOTE: Observe installation position of clutch pedal switch in bearing bracket upper assembly hole. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased of the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified values are obtained: - Connect multimeter to measure voltage between terminal -1- and Ground (GND). - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring for open circuit between 2- pin harness connector terminal -1- and central electrics using wiring diagram. If the specified values are obtained: - Remove wiper arms and plenum chamber cover. Service and Repair Seat Heater Switch: Service and Repair Switches In Instrument Panel, Removing And Installing Switches consists of a switch housing and trim plate with relevant symbol. The trim plate is clipped onto the switch housing. If the trim is released instead of the switch during removal, the trim must be re-clipped onto the switch housing afterwards. Remove switches with connected wiring from instrument panel opening prior to disconnecting electrical connection on rear of switch. If necessary, temporarily remove switch to the left of of the switch to be removed/replaced to allow sufficient access to the wiring. NOTE: Switch blank-out covers (where applicable) are removed in the same manner as switches. CAUTION! - Be careful not to damage instrument panel when removing switch. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. Heated Seat Control Module/regulator, Removing And Installing Removing Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor: Locations Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor Location G39 Page 5338 With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Overview Clutch Pedal Assembly: Service and Repair Overview 5 Speed Manual 02J Clutch Controls, Servicing I-Assembly overview-pedal cluster II-Assembly overview-hydraulics. Note: Disconnect battery ground strap. - For vehicles with coded radio obtain radio code. - Lubricate all bearings and contact surfaces with MOS2 grease. Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 3748 - Disconnect 2-pin connector from Secondary Air Injection (AIR) Solenoid Valve -N112- (arrow). Vehicles with engine code BDF - Disconnect 2-pin connector from Secondary Air Injection (AIR) Solenoid Valve -N112- (arrow). Continuation for all vehicles - Measure resistance between terminals of solenoid valve. Specified value: 25.0...35.0 Ohms If specified value is not obtained: - Replace Secondary Air Injection (AIR) Solenoid Valve -N112-: Vehicles with engine code AFP, item 5, - Vehicles with engine code BDF, item 25. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Page 1091 - Apply adhesive tape to the instrument panel under seat heater switch -1- or the blank cover if the vehicle does not have heated seats and using a flat screw driver -A-, remove the seat heater switch or cover. - Insert assembly tool T10034 into seat heater switch opening, release the clip holding the ESP or ASR switch -2- and pull it out of instrument panel ^ Insert assembly tool T10034 into ESP or ASR switch opening, release the clip holding the emergency light switch -3- and pull it out of instrument panel. ^ Disconnect connector from the emergency light switch ^ On new emergency light switch (1J0 953 235 J 01C) reconnect connector and install switch into instrument panel ^ Reinstall ESP or ASR switch and seat heater switch into in the instrument panel and remove adhesive tape ^ Check turn signal and emergency light switch for correct operation ^ Check all turn signal and emergency light switch bulbs for illumination and replace as required ^ Destroy and properly dispose of removed part(s) Page 2833 Oxygen Sensor: Locations Bank 1, Sensor 2 Oxygen Sensor Oxygen Sensor Location G130 Page 4873 - Fit retainer -A- to master cylinder operating rod -B-. - Press clutch pedal in direction of arrow to engage. Ensure correct location. - Fill brake fluid reservoir up to "max" marking with brake fluid. Bleeding clutch system when fluid level is below "min" marking. Page 2762 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Page 1521 Part 1 Tools and Equipment Strut / Shock Tower: Tools and Equipment Strut Assembly Socket AST tool# 2069 A Strut socket for Audi vehicles. - Steel Construction - Black-Oxide Finish - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5108 Test Step 12 Page 4461 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 5901 S 1054TX T-50 - T-50 Torx Socket S 3054 X-10 - 10mm, 12-Pt. Socket Page 3373 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 6- pin harness connector for open circuit according to wiring diagram. Terminal -4- + socket 5: Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 6-pin harness connector terminal -3- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms Aging Check Oxygen Sensor 1 Aging, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1788/10 engine speed adjuster Test conditions - Coolant temperature at least 85 °C display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX Locations Brake Fluid Pressure Sensor/Switch: Locations G201 - Brake Pressure Sensor 1 (vehicles with ESP) Page 3914 23 - Engine Coolant Temperature (ECT) sensor - G62 -. - Blue. - For Engine Control Module (ECM). - With Engine Coolant Temperature (ECT) sensor - G2 -.. - If necessary, release pressure in cooling system before removing. - Check. - Connector terminals -1- and -3- for Engine Coolant Temperature (ECT) sensor - G62 -. - Terminals - 1 - and -3- are gold plated. 24 - Air Cleaner. 25 - Engine Speed (RPM) Sensor - G28 -. Check. 26 - O-ring. Always replace. Page 1160 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Powertrain Management/Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Page 2707 Engine Control Module: Testing and Inspection Engine Control Module (ECM) Voltage Supply, Checking With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuses 10 and 29 OK - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Generator OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 Page 228 Vehicle Information Sunroof and Central Control Module -J393- Diagnosis Technical Background Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof being interrupted while in operation, or a faulty central control module. Production Solution No production change required. Service Symptoms Sunroof inoperative. Sunroof will not close (stuck open or stuck open in the tilt position). Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position). Warranty When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3400 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4527 Fig. 5 Pulling out starter bushing Fig. 6 Driving in starter bushing - Lubricate bushing mounting before driving in. Fig. 7 Removing and installing multifunction TR switch Location: Multi-function TR switch is located on rear of the transmission. Switch ignition off, open hood. - Disconnect wiring connector from multifunction TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order of removal. Insert switch so that each pin rests on a slope of detent segment. - Tighten bolt to 10 Nm. Page 487 - Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 12. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-. See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Throttle Position Sensor/Testing and Inspection If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Checking voltage supply and wiring to control module - Connect multimeter to connector terminals 2 + 6 for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. - Connect test box to control module wiring harness connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram: Terminal 1 + socket 92 Terminal 2 + socket 83 Terminal 3 + socket 117 Terminal 4 + socket 84 Terminal 5 + socket 118 Terminal 6 + socket 91 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm Page 554 - Read off supply voltage for Engine Control Module (ECM) in display field 2. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Evaluating display group 4, display field 2 - control module voltage supply Page 196 Seat Heater Control Module: Locations Passenger Heated Seat Control Module J132 - Passenger's heated seat control module Oxygen Sensor and O2 Sensor Control After TWC, Checking Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control After TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (After Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair terminals 3 and 4 in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head free of leaks - Coolant temperature at least 85 °C = display group 04, display field 3 Functional check - Press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle (connecting scan tool and selecting engine electronics control module. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -3-, and -0- to input display group number 30 (030) and press - Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 - Check status of oxygen sensor control after Three Way Catalytic Converter (TWC) (display field 2). A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 4908 - Drive off CV using drift - Installation position for left axle shaft see Fig. 6 - Installation position for right axle shaft see Fig. 7 - Before installing on CV joint, coat sealing surface with D 454 300 A2. 9. Spring washer - Installation position see Fig. 3 10. Inner CV joint - Only replace complete - Pressing off see Fig. 2 - Pressing on see Fig. 5 - Greasing - Checking 11. Gasket - Always replace - Adhesive surface on constant velocity joint must be free of oil and grease! - Remove protective foil and stick gasket on joint. 12. Circlip - Use VW161A to remove and install 13. Axle shaft, left (solid shaft) 14. Clamp - Tensioning see Fig. 9 - Always replace 15. CV joint boot - Check for tears and chafing - Material: Hytrel (polyelastomer) 16. Vibration damper - Applies only for some vehicle versions 17. Hose clip - Tensioning with pliers VAG 1682 see Fig. 8 - Always replace 18. Spring washer - Installation position see Fig. 4 19. Bolt - 35 Nm (26 ft. lbs.) 20. Heat shield 21. Thrust washer - Installation position see Fig. 4 22. Circlip - Insert in shaft groove - Always replace 23. Outer CV joint - Only replace complete - Removing see Fig. 1 - Installing: drive on shaft to stop with plastic hammer - Greasing - Checking Fig. 1 Outer CV joint, removing Drive joint off axle shaft with firm blow from aluminum hammer. Page 5105 Test Step 3 - 6 Page 5849 Battery: Description and Operation General Information NOTE: The battery is one of the most important electrical components in the modern automobile. A battery that provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and optimum service life, batteries must be checked, serviced and maintained as per the instructions. Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have increased due to additional safety and convenience features (electrical consumers) being installed. The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues. However, due to physical and chemical limitations, it is not yet possible to consider automobile batteries as being totally maintenance free. A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as well as improved charge stability over a longer period of time. Simplified checking of these batteries is also achieved with the charge indicator ("magic eye"). Page 3681 - When transmission has been securely supported, remove bolts for transmission carrier (arrows). - Remove pendulum support (arrows). - Lower transmission approx. 60 mm (2.4 in.) -a-. - Disconnect black connector from sensor. - Remove bolt and take sensor -1- out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 2243 Timing Chain: Tools and Equipment Bracket for Chain Adjuster AST tool# 3366 Used when removing and installing the timing chain adjuster. VW and Audi 4, 6 and 8 cylinder engines with 5 valves per cylinder. - Used for R and R of the Timing Chain Adjuster - Applicable to Many VW and Audi Models Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: 3242 - Locking Pin Page 3929 Fuel Pressure Regulator: Testing and Inspection The fuel pressure regulator regulates the fuel pressure relative to the intake manifold pressure. The specified value for the check is dependent upon the working pressure of the fuel pump. This is approx. 3.0 bar. Special tools and equipment - VAG1318 pressure gauge - 1318/10 adapter - 1318/11 adapter - 1318/16 hose adapter - VAG1921 hose clip pliers Test sequence Page 823 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Page 6570 - Install felt strips on both sides of the center air outlet at white arrows directly behind locking points (black arrows) as shown. Note: DO NOT cover locking points (black arrows). - Reinstall center air outlet. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 365 Control Module HVAC: Description and Operation Fresh Air Blower Control Module -J126- Fresh Air Blower Control Module -J126Function: On vehicles with Climatronic, controls fresh air blower speed depending on voltage signal. Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4052 - Check secondary winding on terminal 4 between Cyl.1 + Cyl.6 - Cyl.3 + Cyl.4 - Cyl.2 + Cyl.5 Specified value: 3.6 - 4.4 kohms If the specified values are not obtained: - Replace ignition coil -N152-. Refer to item 7, See: Service and Repair If the specifications are not obtained: - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Tires - Vehicle Inspection After A Blowout Technical Service Bulletin # 4401-02 Date: 010627 Tires - Vehicle Inspection After A Blowout Group: 44 Number: 01-02 Date: June 27, 2001 Subject: Inspecting Surrounding Area on Vehicle for Damage if Customer Has Experienced a Tire Blow-Out Model(s): All Supersedes T.B. Group 44 number 01-01 dated Apr. 24, 2001 Service If a customer has experienced a tire blow-out or has operated the vehicle with a deflated tire until it is severely damaged or destroyed: - Inspect the wheel well and surrounding area for damage to parts such as the wheel liner, ABS sensor wires (if equipped), brake lines, hoses, etc which a damaged tire may have caused. - In addition, if the affected tire is the right rear tire, make sure to inspect the fuel tank and filler neck for abrasion damage and leakage. - Repair any damage found or damaged part. - Report all tire related fuel system damage to The Volkswagen Technicians Helpline at 1-800-678-2389. - Refer to the customer letter as shown for additional information. Page 5686 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 3660 Page 1360 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Page 26 NOTE: - Three attempts to enter secret number are immediately possible. The next three attempts are only possible after a minimum of 10 minutes (if the ignition remains switched on during this time and OBD program is exited via the function 06 "End Output"). - Waiting period between each three attempts doubles each time up to a maximum of 255 minutes. - Press buttons -1- and -0- to select "Adaptation" function 10. Indicated on display Rapid data transfer Q 10 - Adaptation - Confirm entry with -Q- button. Indicated on display Adaptation Enter channel number XX - Press buttons -2- and -1- to select "Channel 21". - Press -Q- button to confirm input. If this appears on display Function is unknown or -> cannot be carried out at the moment - Repeat adaptation function and secret number. Indicated on display Channel 21.........Adapting 2 -> <-1 3-> The top line of the display shows that 2 ignition keys are adapted to the system. - Press -> button. Indicated on display Channel 21.........Adapting 2 -> Enter adaptation value XXXXX - Press button -0- four times and then enter the total number of all ignition keys to be adapted, including existing key (e.g.: for a total of three ignition keys, enter "00003"); max. possible Qty.: 8. - Press -Q- button to confirm input. Indicated on display for 3 ignition keys to be adapted Channel 21 Adapting 3 Q <-1 3-> - Press -Q- button to confirm input. Indicated on display Channel 21 Adapting 3 Q Store changed value? - Press -Q- button to confirm input. Indicated on display Channel 21 Adapting 3 -> Changed value is stored Page 4922 - Remove bearing bracket bolts -1- on both sides of rear axle, and lower rear axle. Installing - Bleed brakes. Grease bonded rubber bushings Grease bonded rubber bushings with assembly paste before installing rear axle. - Install in reverse sequence - Check steering wheel position during test drive. - Check wheel alignment if steering wheel is not in straight ahead position . Tightening torque: Shock absorber to body 75 Nm (55 ft. lbs.) Use new bolts! Bearing bracket to rear axle 80 Nm (59 ft. lbs.) Use new nuts and bolts! Power Window Switches In Driver's Door, Removing And Installing Power Window Switch: Service and Repair Power Window Switches In Driver's Door, Removing And Installing Power Window Switches In Driver's Door, Removing And Installing NOTE: Window switches in driver's door cannot be removed individually. The complete door control unit must be replaced. Removing - Remove driver's door release handle. - Remove door release handle with controls upwards from door trim. - Disconnect electrical connector. - Remove screws -arrows- and remove complete control part. Installing Install in reverse order of removal. Page 4838 Valve Body: Service and Repair 5 Speed Automatic 09A Servicing Valve body, servicing Sequence for removing and installing CAUTION: Do not run file engine or tow the vehicle with the valve body cover removed or when there is no ATF in the transmission. Note: The valve body or the solenoid valve wiring harness can also be removed with the transmission installed. - Always replace a valve body which is fouled or faulty. 1. Plug, 15 Nm - Always replace seal = Fig. 1 - Checking ATF level and topping up 2. Overflow pipe 3. Drain plug, 40 Nm - Only remove if oil is to be drained - Removing = Fig. 3 4. Oil seal - Always replace 5. Transmission - housing Page 2495 Part 2 Page 5535 Note: ^ Follow the brake lathe manufacturer's instructions for set-up and machining. ^ Wash the brake disc with a soap and water solution upon completion of resurfacing to remove all machining particles. ^ Re-measure brake disc thickness in 4 locations using either the Pro Cut disc thickness measuring tool Part No.50-902 or the Hunter disc thickness measuring tool Part No.25-99-2, to verify that minimum thickness is still exceeded. If recorded brake disc measurement is less than the minimum thickness, the brake disc MUST be replaced. Note: ^ Measure brake disc lateral run out using Pro Cut Disc Lateral run out measuring kit Part No. 50-700FC or the Hunter Disc Lateral run out measuring kit Part No.25-128-2 with a dial indicator. Run out must not exceed 0.1 mm. Page 3412 - Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 12. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-. See: Sensors and Switches - Computers and Control Systems/Throttle Position Sensor/Testing and Inspection If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Checking voltage supply and wiring to control module - Connect multimeter to connector terminals 2 + 6 for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. - Connect test box to control module wiring harness connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram: Terminal 1 + socket 92 Terminal 2 + socket 83 Terminal 3 + socket 117 Terminal 4 + socket 84 Terminal 5 + socket 118 Terminal 6 + socket 91 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: Page 4415 Test Step 12 Page 3532 - Connect multimeter between terminal 2 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 4-pin connector terminal 2 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with 2-pin clutch vacuum vent valve switch - Check wire between test box and 2-pin connector for open circuit according to wiring diagram. Terminal 2 + socket 39 Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch - Check wire between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 39 Wire resistance: max: 1.5 Ohm Page 3732 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Connect multimeter to measure voltage between test box sockets -2- + -54-. - Switch ignition on. - Lift vehicle at left-front. - Rotate front wheel and observe voltage display. Specified value: between 0 and at least 4 Volts, fluctuating. NOTE: If necessary, hold the right-front wheel to prevent it from turning. If the display does not fluctuate: - Check wiring to speedometer/speedometer sensor. - Check DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 5685 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 4108 Spark Plug: Application and ID Engine Code AFP Spark plugs 1) VW Audi 101 000 035 AH Manufacturers Code BKR 5 EKUP Electrode gap max. 0.7 Tightening torque 25 Nm (18 ft lb) 1) Use tool T10029 for disconnecting and connecting the spark plug connector. Remove and install the spark plugs using tool 3122B Page 1381 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 428 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping EPC Warning Lamp Operation Malfunction Indicator Lamp: Description and Operation EPC Warning Lamp Operation Electronic Power Control (EPC) Warning Lamp (Malfunction Indicator Lamp For Electronic Accelerator [E-Gas]) In Instrument Cluster, Significance The EPC warning lamp is the Malfunction Indicator Lamp for the electronic accelerator (E-gas) system. Location of EPC warning lamp The engine control module checks all the important functions of the electronic accelerator system after switching the ignition on. The instrument cluster switches the EPC warning lamp on for about 1 second during the test of this component. If a malfunction is recognized during the test, the lamp will light continuously. If malfunctions are recognized in the electronic accelerator system (EGas) when the engine is in operation, the engine control module will send a message to the instrument cluster, and the instrument cluster will switch on the EPC warning lamp (these malfunctions are indicated in the DTC table). Simultaneously, an entry is made in the engine control module DTC memory. Page 4287 ^ ALL fault memories must be interrogated and erased. Note: Failure to erase ALL fault memories may cause "Update - Programming" (flashing) procedure to fail! - Select Diagnosis function 06 "End output". - Select Diagnosis function 00 "Collection services". - Select "Check DTC memory - complete system". which will interrogate all fault memories. - Erase ALL fault memories. Once ALL fault memories have been erased: - Select vehicle system "01-Engine electronics". - Select "Update - Programming" option at bottom of screen (arrow). CAUTION! Once "Update - Programming" function has been started, switching ignition OFF or disconnecting the diagnostic connector may completely destroy the ECM. "Update - Programming" (flashing), performing Page 3602 - The O2S sensor has been damaged by leaded fuel Checking basic voltage for oxygen sensor 2 - Remove protective cover (arrows) and disconnect 4-pin harness connector (brown) -1 - to oxygen sensor after Three Way Catalytic Converter (TWC) -G130-. - Connect multimeter using auxiliary cables from VW1594 to measure voltage at terminals 3 + 4 (harness connector to Motronic Engine Control Module (ECM)). - Start engine and measure basic voltage. Specified value: 0.400-0.500 V - Switch ignition off. If the specified value is not obtained: - Check oxygen sensor wiring. If the specified value is obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking oxygen sensor wiring, oxygen sensor 2 - Remove wiper arms and plenum chamber cover. Page 2849 - Connect multimeter for voltage measurement to terminals 3 + 4 of connector to Engine Control Module (ECM) and measure primary voltage. Specified value: 0.40 to 0.50 Volts - Switch ignition off. If specified value is not obtained: - Test oxygen sensor wires. If specified value is obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- Bank 1: Vehicles with engine code AFP, item 9, - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 1504 Heated Glass Element Switch: Service and Repair Switches In Instrument Panel, Removing And Installing Switches consists of a switch housing and trim plate with relevant symbol. The trim plate is clipped onto the switch housing. If the trim is released instead of the switch during removal, the trim must be re-clipped onto the switch housing afterwards. Remove switches with connected wiring from instrument panel opening prior to disconnecting electrical connection on rear of switch. If necessary, temporarily remove switch to the left of of the switch to be removed/replaced to allow sufficient access to the wiring. NOTE: Switch blank-out covers (where applicable) are removed in the same manner as switches. CAUTION! - Be careful not to damage instrument panel when removing switch. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. Rear Window Defogger Switch -E15-, Emergency Flasher Switch -E3- And ASR/ESP Switch, Removing And Installing Removal and installation is the same for all switches. Locations Trunk Lamp Switch: Locations F5 - Luggage compartment light switch Page 5693 Volkswagen Canada, Inc. Page 4036 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Page 3435 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 3366 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the oxygen sensor control in display field 1 does not fluctuate as stated: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values in display field 1 are not obtained even after a road test or the value does not fluctuate by at least 2 %: - Check oxygen sensor (before Three Way Catalytic Converter (TWC)) aging. Evaluating display field 32, display field 1: Oxygen sensor learned values before Three Way Catalytic Converter (TWC) Page 2978 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Locations Brake Fluid Level Sensor/Switch: Locations F34 - Brake fluid level warning switch Page 3067 If no malfunctions are found in wire: Vehicles with engine code AFP - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Vehicles with engine code BDF - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Continuation for all vehicles Range A displays resistance values for the temperature range of 0...50 degree C, range B displays resistance values for the temperature range of 50...100 degee C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 189 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Locations Steering Mounted Controls Communication Module: Locations J453 - Control module for multi-function steering wheel Page 635 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 1205 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Bridge harness connector terminals -1- + - 3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor - G70-, item -4-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display reads approx. 140 °C: Suspension - Insufficient Data On Vehicle Label Alignment: Technical Service Bulletins Suspension - Insufficient Data On Vehicle Label Condition Vehicle Data Label, Suspension PR. Numbers Missing To properly align the vehicle, the PR. number must be used to identify the correct vehicle alignment specifications. Specifications can be found in the Repair Manual - Repair Group 44. 44 06 09 Aug. 28, 2006 2005561 Supersedes T.B. Group 44 number 03-01 dated April 15, 2003 due to updated information. Technical Background Insufficient information on label. Production Solution PR. numbers are included on Vehicle Data Label as of: - Jetta - VIN: 3VWSK69M43M098184 (approx. build date 11/12/2002). - New Beetle - VIN: 3VWCD21C23M428513 (approx. build date 11/12/2002). For vehicles produced prior to the above VINs, the PR. number may be missing from the label. Service Page 5097 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Page 4667 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 1249 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 4-pin harness connector -1- to Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130-. Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -1- and -2(harness connector to Engine Control Module (ECM)). - Start engine and run at idle - Measure voltage supply and observe display group 41, display field 4. Display: Htg.aC.ON - Specified value: 11.0-14.5 V Display: Htg.aC.ON/Htg.aC.OFF (alternating) - Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 3091 - Measure resistance between terminals -2- + -3- of switch. Specified value with brake pedal not depressed: 1.5 ohms Specified value with brake pedal depressed: max. Infinity ohms If the specified values are not obtained: - Replace brake light switch -F- and brake pedal switch -F47-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If the specified values are obtained: - Connect multimeter to measure voltage between terminal -1- and Ground (GND). Specified value: at least 11.5 V - Connect multimeter to measure voltage between terminal -2- and Ground (GND). - Switch ignition on. Specified value: at least 11.5 V If the specified values are not obtained: - Check wiring between 4-pin harness connector terminals 1 and 2 to central electric using wiring diagram. If the specified values are obtained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprockets Mounting bolts 100 Nm Vibration damper Mounting bolt 100 nm + 1/4 turn Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 5101 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Transmission Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant 40 - Multi-Function TR Switch -F125- (pin 2) Page 5770 Wheel Speed Sensor: Locations Left Rear ABS Wheel Speed Sensor G46 - Left Rear ABS Wheel Speed Sensor Page 5983 Page 3617 Possible causes of malfunction if oxygen sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) - The O2S sensor has been damaged by leaded fuel Checking oxygen sensor wiring for oxygen sensor 1 - Remove wiper arms and plenum chamber cover. Page 4752 Torque Converter: Description and Operation 4 Speed Automatic 01M Torque converter The ATF pump is driven via the torque converter. When installing the torque converter, ensure that both drive pins engage in the recesses in the ATF pump inner wheel. There are different types of torque converter, which can be identified by the code letters (arrow). (Transmission installed) Page 4682 - Pull locking cable out of steering lock -1-. - Press down sleeve on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Press tabs of retaining clip together -arrows-. - Pull locking cable out of selector mechanism. Installing Note: When installing ensure that the routing of the locking cable is correct. - Locking cable must not be kinked. - Adjust locking cable after installing. - Shift selector lever into "P" position. - Press locking cable into support bracket on selector lever housing until tabs on retaining clip -arrows- spring outward. - Attach locking cable in locking lever. - Turn ignition key to "ignition on" position. - Push locking cable into steering lock. - Push clip into locking cable. Ensure that clip is properly located. - Adjusting locking cable. Locations Manifold Pressure/Vacuum Sensor: Locations G71 - Manifold Absolute Pressure (MAP) sensor Page 3728 Vehicle Speed Sensor: Locations Vehicle Speed Sensor (VSS) G68 - Vehicle Speed Sensor (VSS) With Manufacturer's Scan Tool Variable Induction Control Valve: Testing and Inspection With Manufacturer's Scan Tool Intake Manifold Tuning (IMT) Valve -N156-, Checking - Perform check only if performance is poor. - The intake manifold change-over from long to short intake ports occurs at approx. 4000 RPM. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1390 hand vacuum pump - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set Checking function - Start engine and run at idle. The change-over barrel in intake manifold is positioned at short passageway. - Fully depress accelerator pedal, then release before 4000 RPM. The actuating element must rotate the barrel in the intake manifold (arrow). If the positioning element does not perform the change-over sequence: - First check activation of Intake Manifold Tuning (IMT) valve -N156- via output Diagnostic Test Mode (DTM). If the activation is OK: - Connect scan tool or vehicle test system. Sensor For Transverse Acceleration (Vehicles With ESP) Lateral Accelerometer: Locations Sensor For Transverse Acceleration (Vehicles With ESP) G200 - Sensor for transverse acceleration (vehicles with ESP) Page 2244 3391 - Camshaft Alignment Tool 6700 - 1.8T Tensioner Holder Set Page 5034 Allocation The cable locks no longer need to be replaced following disassembling. - Spread a small quantity of polyurea grease on pins -arrows- of gear change lever -1- and relay lever-2-. Note: Always replace securing clips -3- and -4- after disassembling. - Secure gear selector cable with securing clip -3- and gate selector cable with securing clip -4-. Continued for all selector mechanisms Align gear lever housing parallel to body. Distance to body must be same on both sides. Adjusting selector mechanism Refer to Adjustments. Tightening torques Selector housing to body 25 Nm Cross support to body 25 Nm Selector cable support bracket to transmission25 Nm Page 1575 Fuel Pressure: Specifications Residual Pressure After 10 minutes there must be a residual pressure of at least ................................................................................................................................ 2.0 bar. Page 4211 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Description and Operation Electronic Throttle Control Module: Description and Operation Function of the Electronic Throttle Control System In the electronic throttle control system, the throttle valve is not actuated by a cable from the accelerator. There is no mechanical connection between the accelerator and throttle valve. The accelerator position is communicated to the engine control module by two throttle position sensors (variable resistance, accommodated in a casing), which are connected to the accelerator. The accelerator position (determined by the driver) is a main input variable for the engine control module. An electric motor (throttle actuator) in the throttle valve control module -J338- actuates the throttle valve over the entire range of engine speeds and load. The throttle valve is actuated by the throttle actuator under instructions from the engine control module. When the engine is off and the ignition is turned on, the engine control module controls the throttle actuator precisely, following specifications from the throttle position sensor. That is, if the accelerator is half-way to the floor, then the throttle actuator opens the throttle valve to the same angle; the throttle valve is then opened approximately half-way. When the engine is running (under load), the engine control module can open or close the throttle valve independently of the sensor. As an example, the throttle valve can already be completely open, even though the accelerator has only been pressed half-way down so far. This has the advantage of preventing throttling loss at the throttle valve. Under certain load conditions, this also results in significantly reduced emissions and improved fuel consumption. It is wrong to believe that electronic throttle control only consists of two components. It is a system which contains all components needed to help determine, regulate, and supervise the throttle valve position (e.g. the throttle position sensor which measures the accelerator position, the throttle valve control module, the EPC indicator lamp, the engine control module). Page 2379 ^ Cut wiring at this point to old connector and remove. ^ Fold over and tape brown/white wire of original harness using vinyl tape (see above - Unused wiring, taping back to harness). Fuel pump / fuel gauge sensor overlay harness, connecting to factory harness ^ Connect three wires of overlay harness to their mating factory harness wires using crimp connectors: Part No:111971939B (blue) for blue/red and brown wires Part No:111971941A (light yellow) for violet/black wire Tip: Diesel vehicles, only connect violet/black wire. ^ Install new fuel pump/fuel sender unit. Connect overlay harness to fuel pump / fuel gauge sensor. ^ Install cover for fuel pump/fuel gauge sensor. Fuel pump / fuel gauge sensor overlay harness, routing to instrument cluster ^ Route fuel pump overlay harness, following original harness routing along passenger side floor sill towards "A" pillar and secure using interior vinyl tape. ^ Continue fuel pump overlay harness routing along original harness routing, forward of instrument panel cross member, towards instrument cluster (do not secure with tape at this time). Instrument cluster harness, preparing factory harness ^ Remove insulating tape from factory harness on instrument cluster blue connector back to the point where it joins with the main harness. Tip: Some wires may be looped under tape, be careful not to cut wires while removing tape. Pull any excess (looped) wire in original harness towards blue connector. Instrument cluster wiring, special procedures Page 916 Low Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch, Electrical Checks Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10.8mm x 1.8mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan V7 (via the coolant fan control module J293 ) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). A/C Pressure Switch, Functional Checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch N25 engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), F129 switches A/C clutch off. - Check cooling fan function. When system pressure increases, F129 causes coolant fan V7 to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condensor is blocked), F129 switches A/C clutch off. Page 136 Door Module: Diagrams Door Control Module, Driver And Passenger Side Page 3288 After successful DTC memory check: Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -5- to select "Erase DTC memory" function 05. Indicated on display: Rapid data transfer Q 05 Erase DTC memory - Press -Q- button to confirm input. Indicated on display: Rapid data transfer -> DTC memory is erased! DTC memory is erased. - Press -> button. Indicated on display: Rapid data transfer HELP Select function XX NOTE: - If this appears in the display, the test sequence is faulty. WARNING! DTC memory was not checked - If this appears in the display, the test sequence is faulty. Rapid data transfer -> DTC memory was not checked - Follow test sequence exactly: first check DTC memory, repair malfunctions) if necessary, then erase. With Manufacturer's Scan Tool Idle Speed: Testing and Inspection With Manufacturer's Scan Tool Idle Speed, Checking NOTE: - Idle speed, ignition timing and CO content are not adjustable. - The idle speed is regulated to specified value by the throttle position sensor in conjunction with the DIS function. - CO content regulated by Oxygen Sensor (O2S) control. Malfunctions in oxygen sensor control are detected in On Board Diagnostic (OBD) and stored as DTCs in DTC memory Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Coolant temperature at least 85 °C See display group 004, display field 3. - Intake air temperature less than 60 °C See display group 004, display field 4. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes - Leave VAG1551 Scan Tool (ST) connected. - Continue running engine at idle speed. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -0- and -1- to input display group number 1 (001) and press -Q- button to confirm input. Indicated on display: (1-4= display fields) System in basic setting 1 -> 1234 NOTE: In the "Basic Setting" function the Evaporative Emissions (EVAP) canister purge regulator valve -N80- is closed and the air conditioner compressor is switched off - Check adjustment conditions for basic setting in display field 4. Page 1569 After tightening lock nut -1- it is possible for adjustment to vary slightly. If value does not vary more than 2' from specification, adjustment is ok. Ensure that boots are not twisted after adjustments are completed. 4 Speed 01M Transmission Fill Plug: Locations 4 Speed 01M Transmission 4 Speed 01M Transmission 1 Level Plug (with Overflow Line Tube)................................................................................................ .............................................................. 15 Nm 2 Fill Plug (with protective cap) Note: Always replace protective caps without spring retainers. The cap secures the plug. Tools and Equipment Timing Belt: Tools and Equipment Timing Belt Spanner Wrench AST tool# H 2587-2 Used for adjusting the timing belt tension and is comparable to VW tool# T10020. Applicable: 1999 and later VW Golf, Jetta, Passat, and 1999-2003 VW Beetle with 2.0L gas engine and 1.9L T.D.I. diesel engine. - Used for Adjusting the Timing Belt Tension - Applicable to 1999 and later VW Golf, Jetta, Passat, and 1999-2003 VW Beetle with 2.0L Gas Engine and 1.9L T.D.I. Diesel Engine - 2.0L Turbo (BPY) Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Service and Repair Fuel Tank Unit: Service and Repair Fuel delivery module, removing and installing Special tools, equipment, test and inspection devices; required accessories - 3217 ring nut wrench - VAG 1332 torque wrench (40 - 200 Nm) or equivalent Removing - Review safety measures before starting work. NOTE: The battery ground strap must eventually be disconnected in the further course of work. Check whether the vehicle has a coded radio system. It may be necessary to disable the theft-deterrent feature by entering the appropriate code. - Disconnect the battery ground strap with ignition off. - Fold rear seat forward. - Remove cover under seat. Page 846 ^ Indicator lamp for oil pressure (K3) must illuminate for approximately 3 seconds after the ignition is turned on. ^ Oil temperature at least 80°C Oil pressure switch, checking - Remove the 1.4 bar oil pressure switch (F1) (black insulation) and screw it into the tester. - Screw the tester into the oil filter housing in place of the oil pressure switch. - Ground the tester brown lead H. - Connect the V.A.G 1527 B diode test lamp to the battery positive terminal (+) and to the oil pressure switch using the auxiliary cables from V.A.G 1594 A. The Light-Emitting Diode (LED) should not illuminate. If the LED illuminates: Replace the 1.4 bar oil pressure switch (F1). If the LED does not illuminate: Let the engine continue to idle. The light-emitting diode should light at 1.2-1.6 bar. Otherwise, replace the 1.4 bar oil pressure switch (F1). Oil pressure, checking Test condition ^ The VAG 1342 oil pressure test instrument is riot connected ^ Oil temperature at least 80°C Test sequence Start the engine and let it idle. Specification: oil pressure: at least 2.0 bar - Increase engine speed. ^ The oil should be at least 2.0 bar at 2000 rpm and 80°C oil temperature. ^ The oil pressure may not exceed 7.0 bar - Replace oil pump if necessary. Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2106 AC-Bu Page 4359 Fig. 3 Installing corrugated washer and inner and outer plates in clutch housing - First insert corrugated washer. - Insert 2 mm thick outer plate. - Insert remaining inner and outer plates. Fig. 4 Inserting inner plate carrier and installing circlip (arrow). - Lift inner plate carrier slightly to install circlip (arrows). Page 858 Ambient Temperature Sensor / Switch HVAC: Service and Repair CAUTION: Before working on the electrical system: - Get radio anti-theft code. - Disconnect battery Ground (GND) strap. NOTES: - After reconnecting battery: - Reactivate vehicle equipment such as radio, clock and power windows. - Activate readiness code Fresh Air Intake Duct Temperature Sensor -G89- (Item # 10 in image), removal - Remove glove box. - Reach behind heating and A/C unit. - Turn temperature sensor 90 ° and pull out. - Lubricate seal with oil when installing. NOTE: If it is not possible to remove sensor as described above: - Remove instrument panel and loosen instrument panel cross member. See: Body and Frame/Interior Moulding / Trim/Instrument Panel/Dash Board/Service and Repair - Partially remove heating and A/C unit. Page 3721 - Measure resistance between terminals of the respective valve for camshaft adjustment. Specified value: 10...18 Ohms If specified value is not obtained: - Replace control housing for camshaft adjustment, item3. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit according to wiring diagram Wire resistance: max: 1.5 Ohms If resistances and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2670 Page 2959 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 2951 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 901 High Pressure Sensor / Switch: Locations High Pressure Sensor G65 G65 High Pressure Sensor in engine compartment, right rear, in refrigerant line Page 2359 With overlay harness taped to guide tube: ^ Apply lubricant over engine overlay harness. (DO NOT use silicone spray). ^ Remove tape on lower end of harness grommet (arrow). ^ Insert guide tube through main harness grommet (arrow) in plenum (passenger side). ^ Pull harness through grommet to third assembly mark on harness. Tip: You must also pull the single wire portion of engine overlay harness into` the plenum along with main portion of overlay harness. ^ Continue harness routing along existing wiring harness across plenum through any existing harness fasteners to left side of plenum (attach with new bolt tie wraps). ^ Continue overlay harness routing into left hand harness channel (second assembly mark at plenum as shown (arrow). Inspect connector for contamination: 1. MY 1999: 10 Pin in wiring harness channel. 2. MY 2000: 14 pin in wiring harness channel. 3. MY 2001: below battery. ^ Clean connector housing as necessary, replace contaminated terminals as necessary (except cavity 9, see below). Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 2919 If indicated voltage does not oscillate: - Remove instrument cluster: - Check wire connection from Engine Control Module (ECM) to Speedometer -G21- according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3701 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Frost Protection to: Antifreeze: G12* Water* -25°C 40% 2.7 Liters 3.6 Liters -35°C 50% 3.0 Liters 3.0 Liters * The amount of coolant can vary depending on vehicle equipment. Page 315 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Ignition System/Service Precautions/Technician Safety Information With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Page 4082 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 4184 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Page 3593 Oxygen Sensor: Locations Bank 1, Sensor 2 Oxygen Sensor Oxygen Sensor Location G130 Page 3930 - Disconnect supply line/hose -1- and collect leaking fuel with a cloth. WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. - Connect VAG1318 pressure gauge using adapters VAG1318/10, /11 and /16. - Open pressure gauge cut-off valve (handle points in direction of flow (arrow)). - Start engine and run at idle. - Check fuel pressure. Specified value: approx. 2.5 bar If the specified value is obtained: Page 1913 - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake drum. - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Page 6221 - Loosen lock nut -1 - Adjust toe by turning tie rod (arrow) to left or right. Position wrench at nut (arrow) on tie rod. NOTE: Ensure tie rod boot is not twisted after adjustment has been completed. Twisted boots wear out quickly. - Tighten lock nut -1- to 50 Nm (37 ft. lbs.) and check toe again to ensure adjustment has not changed If toe adjustment has not moved more than 2' from specification, adjustment is ok. Steering lock (left/right), checking Test required only if: ^ Steering lock differentiates from center more than 2 ^ One side has contact between tire and component. ^ Turning circle left/right differs Distance between front axle components and tires (arrow) must be even at full lock (full turn left/right) If an imbalance exists make correction by turning tie rod left/right. Example: Right steering lock smaller than left. Loosen lock nuts at tie rod ends. - Turn left tie rod (unscrew tie rod end) - Turn tie rod, right side equal amount to left but in opposite direction (turns tie rod end in). - Check total toe. After adjustment total toe must be within specification. Tighten lock nuts. Page 2423 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2866 - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Oxygen Sensor (O2S) And Oxygen Sensor Control Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. - The oxygen sensor (before catalytic converter) has a static regulation and can be differentiated from the oxygen sensor behind catalytic converter via a 6-pin connector. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degrees C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor before catalytic converter must be OK. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor Before TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals - End diagnosis and switch ignition off. If specified values are not obtained: - Test oxygen sensor wires. Page 5592 <-- Place electrical connector -1- into ABS control module and push in direction of -arrow 2- <-- Lock electrical connector to ABS control module by pushing latch down -arrow 3^ If applicable, reinstall secondary air relay box and reinsert harness in support clip ^ If applicable, reconnect electrical connector to brake fluid reservoir <-- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) <-- If applicable reconnect air hose -4- from secondary air pump to air filter box -5<-- Reconnect vacuum line -7- to air box (TDI vehicles only) <-- Reconnect air intake hose to mass air flow sensor and secure with clamp -3<-- Reconnect electrical connector -1- to mass air flow sensor -2^ Reconnect the ground cable (GDN) from the negative (-) battery terminal ^ In the vehicle, remove brake pedal depressor from the brake pedal ^ Proceed to Section D Section D Section D - Code ABS Control Module ^ Connect VAS 5051 to data link connector located under dash left of steering column Page 997 ^ Start engine. ^ Slowly depress brake pedal 15 times. ^ Recheck ECM for DTC. If DTC (P0571) is found: ^ Install new brake light switch. See Installation Procedure below. If no DTC is found: ^ Return the vehicle to customer. Section B - Brake Lights not Operating Correctly If vehicle brake lights do not come on or are constantly on: ^ Using VAS 5051/5052, go to Engine Electronics. ^ Read display value of measuring block 66. Display value should be XX00 with no pedal engagement. ^ Depress brake pedal and display value should change to XX11. If the last 2 digits of either display value are not correct: ^ Install new brake light switch. See Installation Procedure below. ^ If the last 2 digits of both display values are correct: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. Verify the wiring, connectors, grounds, etc. leading to the brake lights. See Repair Manual for appropriate wiring diagrams. Installation Procedure ^ Switch ignition to the OFF position and remove ignition key. ^ Remove the lower dash cover fasteners -1-. ^ Pull cover -2- out of rear holding clips and set cover aside. System Pressure Fuel Pressure: Specifications With Hose to Regulator Connected approx. 2.5 bar With Hose to Regulator Disconnected approx. 3.0 bar Page 4786 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 3904 Checking activation and voltage supply - Connect VAG1527B voltage tester to harness connector terminals of fuel injector to be tested using cables from VW1594. - Operate starter and check activation of fuel injector. The LED must flicker If the LED does not flicker: - Switch ignition off. - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 testbox to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Page 398 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1260 Possible causes of malfunction if oxygen sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) - The O2S sensor has been damaged by leaded fuel Checking oxygen sensor wiring for oxygen sensor 1 - Remove wiper arms and plenum chamber cover. Page 2841 Continuation If the specified value is not obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the valid safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 36, display field 1 - Lambda probe voltage Lambda probe after catalyst Possible causes of malfunction if 02S sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) Page 3282 - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Page 6521 Axle Nut: Tools and Equipment VW/Audi Axle Nut Set AST tool# 6500 Page 4195 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 2375 With overlay harness taped to guide tube: ^ Apply lubricant over engine overlay harness. (DO NOT use silicone spray). ^ Remove tape on lower end of harness grommet (arrow). ^ Insert guide tube through main harness grommet (arrow) in plenum (passenger side). ^ Pull harness through grommet to third assembly mark on harness. Tip: You must also pull the single wire portion of engine overlay harness into` the plenum along with main portion of overlay harness. ^ Continue harness routing along existing wiring harness across plenum through any existing harness fasteners to left side of plenum (attach with new bolt tie wraps). ^ Continue overlay harness routing into left hand harness channel (second assembly mark at plenum as shown (arrow). Inspect connector for contamination: 1. MY 1999: 10 Pin in wiring harness channel. 2. MY 2000: 14 pin in wiring harness channel. 3. MY 2001: below battery. ^ Clean connector housing as necessary, replace contaminated terminals as necessary (except cavity 9, see below). Page 1056 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping With Generic Scan Tool Leak Detection Pump: Testing and Inspection With Generic Scan Tool Check Leak Detection Pump (LDP) Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Leak detection pump (LDP) -V144- must be OK. - Ignition switched off. Test sequence - Remove rear right wheelhousing liner. - Disconnect 3-pin connector of Leak detection pump (LDP) -V144-(arrow). - Measure resistance between terminals 1 + 3 of diagnostic pump. Specified value: 640...720 Ohms - Measure resistance between terminals 2 + 3 of diagnostic pump. Specified value: 12.5...19.5 Ohms 4 Speed Automatic 01M, Locking Cable, Remove & Install Shift Interlock Cable: Service and Repair 4 Speed Automatic 01M, Locking Cable, Remove & Install Locking cable, removing and installing Removing Installation position of locking cable 1. Footwell vents 2. Support/instrument panel 3. Heater unit - Obtain radio code on vehicles with coded radio. - Disconnect battery ground strap. - Pull locking cable clip upward off ignition switch. In addition, it may be necessary to - Remove steering wheel, left trim under instrument panel, steering column trim and steering column adjustment handle to create more space. - Turn ignition key to "ignition on" position. - Shift selector lever into "P" position. - Pull out clip -2- for locking cable -3-. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation A/C Pressure Switch F129 A/C Pressure Switch F129 F129 has three functions: Switches the A/C clutch N25 off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged). - Switches the A/C clutch N25 off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out) - Switches on the second speed coolant fan V7 when refrigerant circuit pressure increases. Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. - A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Page 3630 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor Before TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control Before TWC, Checking, With Manufacturer's Scan Tool. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control Before TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. Page 1769 Engine Oil: Fluid Type Specifications VW Engine Oil Part Number / Specification ................................................................................................................. ............................................................... VW 502 00 Page 2619 Body Control Module: Locations J393 - Central Control Module For Comfort System J393 - Central control module for comfort system Page 5151 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Service and Repair Wiring Harness: Service and Repair Wiring Harnesses And Connectors, Repairing CAUTION! Wiring harness and connector repairs must only be performed using repair kit VAS 1978! Repair kit VAS 1978 contains a detailed instruction manual that outlines all aspects of wiring harness and connector repair. Always follow wiring harness and connector repair measures. Wiring Harnesses And Connectors, Repair Measures CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. - Before beginning wiring and connector repairs, determine and rectify the cause of damage, eg.: pinched between metal parts, Page 976 Warranty Required Parts and Tools Page 2276 - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose -1- and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Continuation for all vehicles - Start engine and let run at idle. - Measure fuel pressure. Specified value: about 2.5 bar positive pressure Vehicles with engine code AFP - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Vehicles with engine code BDF - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Continuation for all vehicles Page 3832 - Check Fuel Pump (FP) current draw as follows: - Reconnect all disconnected fuel lines. - Connect multimeter with electrical current probe to wire of 4-pin connector (terminal 1 arrow) from wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max: 8 amperes NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 709 - Installation position: Lower A-pillar, cove red by trim in footwell - Remove left A-pillar lower trim to remove 20 - Central control module Bolted to bracket on steering column under instrument panel - To remove, remove lower steering column trim first 21 - Hood lock Contact switch for anti-theft alarm - Installation position: In lock carrier Page 5855 - Electrolyte level must align with the internal electrolyte level indicator (lip). This equates to the external "maximum" marking on the battery case. NOTE: On batteries with black housings, obtain accurate electrolyte level readings by illuminating inside of cells with a flashlight Electrolyte level too low - Fill with distilled water using battery filling bottle VAS 5045 (or equivalent) up to the max. marking NOTE: Design of filler support on filling bottle VAS 5045 prevents overfilling of battery cells and subsequent electrolyte leaks. When max. level is reached the flow of distilled water into battery cells stops. CAUTION! - Only use distilled water to top-up batteries. This prevents electrolyte impurities which cause self-discharging. - DO NOT overfill the battery - Overfilled batteries can boil over. - Too little electrolyte reduces the service life of the battery. - Use use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. Only use genuine cell caps of the same construction if lost or damaged. All cell caps must be equipped with an O-ring seal. NOTE: If it becomes necessary to top up the battery with distilled water, always perform a load test afterwards. See: Electrolyte level too high Special tools, testers and auxiliary items needed Page 864 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4862 Clutch Master Cylinder: Service and Repair Master Cylinder Removing and Installing 5 Speed Manual 02J Special Tools and equipment required - 3309 Release tool - 10-208 A Pliers Removing - Remove intake hose -1- , connector -2- and hose -3- from Mass Air Flow (MAF) Sensor. - Remove complete air cleaner housing by unscrewing bolts -4- and -5-. Refer to Powertrain Management. Page 5345 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 4645 Page 4100 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 666 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2817 System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 1582 - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose -1- and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Continuation for all vehicles - Start engine and let run at idle. - Measure fuel pressure. Specified value: about 2.5 bar positive pressure Vehicles with engine code AFP - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Vehicles with engine code BDF - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Continuation for all vehicles Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. With Manufacturer's Scan Tool Engine Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Engine Speed (RPM) Sensor -G28-, Checking The engine speed (RPM) sensor -G28- is a speed and reference mark sensor. The engine will not start if there is no speed signal. If the speed signal fails when the engine is running, it will cause the engine to stall immediately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test sequence - Disconnect grey 3-pin harness connector (arrow) from engine speed sensor. - Measure sensor resistance between terminals 2 + 3 of harness connector to sensor. Specified value: 480-1000 ohms - Check sensor for short between terminals 1 + 2 as well as -1- + -3-. Specified value: infinity ohms If the specified values are not obtained: - Replace engine speed (RPM) sensor -G28-, item 25. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 822 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 6099 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4785 Page 6368 - Unscrew socket head bolt - 2 - and pull steering wheel off steering column. Page 3917 30 - Heated Oxygen Sensor (HO2S) - G39 -. - 50 Nm. - Location: in front of Three Way Catalytic Converter (TWC). - Grease only threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not get into slots on sensor body. - Remove and install using special tool 3337. - Oxygen sensor heater voltage supply via Fuel Pump (FP) relay J17. - Check. 31 - Intake Hose. Make sure it is seated securely. - Press together at front to release. - To Secondary Air Injection (AIR) pump motor - V101 -. Page 3743 Note: Do not use any compressed air in the following test! - Remove intake hose to combination valve on top of air filter -arrow- and blow in with low pressure. The combination valve must be closed. - Start hand pump. The combination valve should open. If the combination valve does not open: Replace combination valve. With Generic Scan Tool Combination Valve, Checking Recommended special tools and equipment - VAG1390 Hand Vacuum Pump Test requirements - No leaks in vacuum lines or hose connections. - Vacuum hoses not clogged or kinked - Pressure hose for Secondary Air Injection (AIR) Pump Motor not clogged or kinked Test sequence Vehicles with engine code AFP NOTE: Do not use pressurized air for the following test. - Remove front noise insulation. - Disconnect vacuum hose from combination valve at Secondary Air Injection (AIR) Solenoid Valve -N112-, item 5. - Connect hand vacuum pump (VAG1390) at vacuum connection to combination valve. Page 5377 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 3411 - Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly. - Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop: - End diagnosis and switch ignition off. If specified values are not obtained: - Disconnect the 6-pin connector at the throttle valve control module (arrow). Check resistance - Measure resistance of Throttle drive (power accelerator actuation) -G186- in Throttle Valve Control Module -J338- between terminals 3 + 5 Specified value: 1.0...5.0 Ohm If specified value is not obtained: - Replace Throttle Valve Control Module -J338-: Wheel Speed Sensor on Front Axle Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Front Axle Note: Removing and installing ABS system components is identical for FS III and FN 3 brake calipers. 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant, G 000 650 2 Wheel bearing housing 3 Hex socket head bolt, 8 Nm (70 inch lbs.) 4 Splash shield 5 Hex bolt, 7 Nm (62 inch lbs.) 6 Wheel bearing ^ Replace each time after removing 7 Screw 8 Brake disc 9 Wheel hub with ABS wheel speed sensor rotor ^ Pressing out and in 10 Circlip Wheel speed sensor for front axle, removing and installing Removing ^ Raise vehicle. Page 14 All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Page 1547 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4044 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated A/T - Pan Gasket Appears to be Leaking Transmission Pressure Test Port: All Technical Service Bulletins A/T - Pan Gasket Appears to be Leaking Group: 37 Number: 01-01 Date: Mar. 5, 2001 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Supersedes T.B. Group Number 37 Number 00-02 to reflect new part number Condition Transmission appears to be leaking around ATF pan gasket. In most cases the leak is NOT caused by the ATF pan gasket, but by the main line pressure plug (arrow). ATF fluid flows down from main line pressure plug to pan seal, giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace with Part No: N 904 142 01 (plug with seal) - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases, a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. Page 164 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2176 - Insert mounting device 2036 and adjust the bearing arrangement to the stud bolt height. - Screw the flexible pressure tubing VW 653/3 into the spark plug thread and provide continuous pressure (min. 6 bar). - Remove the valve springs with mounting lever VW 541/1A and thrust piece VW 541/5. Note: Loosen binding valve collets (keepers) by applying light hammer blows to the mounting lever. - Remove valve stem seals using extruder 3047 A. Installing - To avoid damage to the new valve stem seals, push plastic sleeve -A- onto the valve stem. - Oil valve stem seal -B-, insert it into the press down device 3129 and carefully push onto the valve guide. Page 5879 To ensure battery seats securely, only install batteries with a 10.5 mm battery foot strip and adhere to the following work sequences: - Install battery so battery carrier lug -arrow- engages in battery foot strip cut-out -1-. It must not be possible to move a battery to the left or to the right. Battery is inserted correctly when center cut-out in battery foot strip aligns with threaded hole in battery carrier -arrows- On batteries with a hose for central venting ensure that the hose is not squashed. Only then can the battery vent freely. - On batteries without a hose for central venting ensure that the opening on the upper side of the battery cover is not blocked. NOTE: New generation batteries are equipped with a central gas venting system and integrated flame trap. Function: Gases produced during charging escape through a central opening on the side of the upper cover. The integrated flame trap prevents flammable gases in the battery from igniting. The flame trap is comprised of a small round fiberglass mat with a diameter of 15 mm and a thickness of 2 mm. Working as a one-way-valve, it allows gases produced during charging to vent. Page 2768 If the display does not change: - Disconnect 2-pin harness connector from clutch vacuum vent valve switch -F36-. - Measure resistance between switch terminals -1- and -2-. - Specified value without clutch depressed: max. 1.5 ohms - Specified value with clutch depressed: max. infinity ohms If the specified values are not obtained: - Replace clutch vacuum vent valve switch -F36-. NOTE: Observe installation position of clutch pedal switch in bearing bracket upper assembly hole. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased of the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified values are obtained: - Connect multimeter to measure voltage between terminal -1- and Ground (GND). - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring for open circuit between 2- pin harness connector terminal -1- and central electrics using wiring diagram. If the specified values are obtained: - Remove wiper arms and plenum chamber cover. Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 4906 Constant Velocity Joint: Service and Repair Axle Shaft With Constant Velocity Joint, Servicing Grease quantity and type Constant velocity joints are packed with grease G 000 603: Inner joint NOTE: If necessary, re-grease joint when replacing CV joint boot. Page 1770 Engine Oil: Application and ID ENGINE OIL: Specifications and Viscosity: Your engine was factory filled with an all season high quality engine oil that has a viscosity grade of SAE 5W-40. You can use this oil over all temperature ranges for normal driving. If you need to add oil between oil changes use any high quality petroleum - or synthetic-based oil with correct specifications. If engine oil viscosity grade SAE 5W-40 is not available, you can also use SAE 5W-30. To assure that the oil you use is of the highest quality required by your car the following terms must appear on the oil container singly or in combination with other designations: Gasoline engine: - VW 502 00 or VW500 00 or VW501 01 - ACEA A2 or ACEA A3 - API Service SJ Diesel engine: - VW 505 00 - ACEA B3 or ACEA B4 - API Service CF4 or API Service CG4 General recommendations: If SAE 5W-40 or 5W-3O viscosity grade oil is not available in your area, be sure to always use a viscosity grade suitable for the climate and seasonal conditions that exist where the vehicle is being operated. Always make sure that the oil meets the quality standards listed above. Engine oil identification symbol: Oils of the proper quality for your vehicle will be identified with a new "starburst" symbol A. The starburst symbol indicates that the oil has been certified by the American Petroleum Institute (API). Another oil identification symbol B could be added to the oil container to help you select the correct oil. 1 - The top portion indicates the oil quality by API designations. 2 - The center portion shows the SAE oil viscosity grade. 3 - The lower portion indicates that the oil has fuel saving capabilities. Note: Page 1114 Removing - Apply adhesive tape to instrument panel in area of switch. - Carefully release switch -2- (or switch -3- ) using a knife tip or a flat screwdriver -1- and remove. - Disengage and disconnect electrical harness connectors if necessary Installing - Connect and engage electrical harness connectors. - Insert switch -2- (or switch -3-) into vent and engage. Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Ride Height Alignment: Specifications Ride Height Vehicle trim height, "Zero position" In general! If a value lies outside the tolerance, the vehicle's trim height must be checked first. If the measured values are outside the allowed tolerances, the cause may be an incorrect vehicle attitude. Right-hand drive vehicles or for example vehicles with automatic transmission can lean to one side slightly. This is due to the installation position of components and weight distribution - It is absolutely necessary to measure dimension "a" on left and right hand sides. The O line on the roof means the horizontal position (zero position) of the vehicle. - Correct differences if necessary. It is possible to correct trim height imbalance for front axle by adding weight to top of strut tower and/or adding weight in trunk for rear axle, example: sand bags can be used, approx. 10 kg (22 lbs.) Page 4904 - Push engine/transmission assembly forward with pry bar. - Remove triple roller joint axle shaft. (Arrow points forward) Installing Remove paint residue and/or corrosion on outer joint splines. Coat with oil before installing axle shaft: Splines of outer joint - Thread of outer joint - Wheel hub splines - Contact surface and thread of twelve-point nut - Install axle shaft. - Install outer joint, in as far as possible. - Connect ball joint to control arm with new bolts on old marks. NOTE: Torque ball joint to control arm: 20 Nm (15 ft. lbs.) + 90° further. - Install inner joint to axle shaft. Tightening torque M8 x 18: 20 Nm (15 ft. lbs.) + 90° M8 x 28: 20 Nm (15 ft. lbs.) + 90° M8 x 48: 20 Nm (15 ft. lbs.) + 90° M10 x 23: 50 Nm (37 ft. lbs.) + 45° M10 x 52: 50 Nm (37 ft. lbs.) + 45° - Bolt pendulum support to sub-frame and tighten to 25 Nm (18 ft. lbs.). - Tighten outer joint until outer joint comes in contact with wheel bearing. - Install wheels and tighten lug bolts to 120 Nm (89 ft. lbs.). - Lower the vehicle. Locations Brake Fluid Level Sensor/Switch: Locations F34 - Brake fluid level warning switch Specifications Spark Plug: Specifications Spark Plugs AFP VW Part Number ................................................................................................................................. ................................................. 101 000 035 AH Manufacturer Designation (NGK) ............................................................................................................................................................ BKR 5 EKUP Spark Plug Gap ............................................................................................................. ....................................................................................... 0.7 mm Tightening Torque .......................... ...................................................................................................................................................... 25Nm (18 ft. lb.) Page 242 Sunroof / Moonroof Module: Electrical Diagrams For information regarding diagrams for the Sunroof Control Module, please refer to the Comfort System Diagrams. Without Power Windows With Power Windows Page 5040 - Always replace 12. Gear selector lever - Install so that the master spline aligns with selector shaft - Can be replaced with the selector mechanism installed - Installation position 13. End cover Fig. 1 Removing ball sleeve from selector mechanism cover Before pulling out ball sleeve, destroy plastic cage and remove balls. A - Internal extractor, e.g. Kukko 21/3, 18.5 ... 23.5 mm Fig. 2 Driving ball sleeve into selector mechanism cover Fig. 3 Installing oil seal onto stop Page 1319 - Carry out road test with 2nd person to observe display. Observe safety precautions when carrying out road test. Refer under "Fuel Delivery and Air Induction", See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions - Observe figure displayed in display field 3: Specified value: approx. driven speed Display Group 005 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If no speed is displayed: - Remove wiper arms and plenum chamber cover. Page 2623 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4636 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 3027 - Disconnect 5-pin connector from ignition coil (N152). - Disconnect fuse no. 32 from fuse block. Note: By removing fuse 32, the voltage feed to the injector valves is interrupted. - Completely depress accelerator pedal for wide open throttle. - Check compression pressure with compression pressure tester VAG 1763. - Crank engine until tester no longer shows an increase in pressure. Compression pressure readings: New: 10 - 13 bar Max. wear: 7.5 bar Permissible variation between all cylinders: 3 bar Keyless Entry/Starting - Emblem On Remote Damaged Keyless Start Transmitter: Customer Interest Keyless Entry/Starting - Emblem On Remote Damaged 57 08 12 Nov. 6, 2008 2017009 Supersedes T.B. Group 57 Number 08-02 dated Feb. 14, 2008 to include additional model years. Vehicle Information Condition Key Remote, Emblem (Sign) Damaged VW emblem on remote key is damaged. Technical Background Due to an insufficient finish, the emblem surface may be damaged (scratched) when in contact with other objects. Production Solution Improved finish on emblem supplied with vehicle production as of (CW) 45/2007 (see sticker on B-Pillar for production date). Service EMBLEM REMOVAL WARNING: Make sure your hands are properly positioned out of the way in case the awl slips. Page 2118 Engine Oil: Fluid Type Specifications VW Engine Oil Part Number / Specification ................................................................................................................. ............................................................... VW 502 00 Page 3629 - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 6,4...47,5 Ohm (at room temperature) If specified value is not obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-: Vehicles with engine code AFP, item 9. - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2083 Engine Oil Pressure: Pressure, Vacuum and Temperature Specifications Engine Oil Specifications At Idle And An Oil Temperature Of 80°C Oil Pressure ......................................................................................................................................... ................................................... 2.0 Minimum At 2000 RPM And An Oil Temperature Of 80°C Oil Pressure ......................................................................................................................................... .................................. 3.0 to 4.5 Bar Minimum At Higher RPM With Oil Temperature Of 80°C: Oil Pressure ......................................................................................................................................... ................................ Must Not Exceed 7.0 Bar Page 2701 Engine Control Module: Application and ID Control Module Identification and Equipment Control Module Identification The control module version is displayed when the VAG1551 Scan Tool (ST), the VAG1552 mobile scan tool or the VAS5051 vehicle diagnostic, testing and information system is connected and "Engine Electronics" address word 01 is selected See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Manufacturer's Scan Tool/Connecting VAG 1551 Scan Tool Technical data Engine code AFP System designation Motronic ME7.1 Exhaust emissions conform to: OBD II On Board Diagnostic (OBD) yes Output Diagnostic Test Mode yes Operating mode of data transfer to VAG1551/1552 Rapid data transfer DTC memory Non-volatile memory 1) Readiness Code Memory Volatile memory 2) Heated Oxygen Sensors (HO2S) 2 sensors Knock control 2 knock sensors Twin-path intake manifold yes Variable valve timing no Charge pressure control no Secondary Air Injection (AIR) system yes 1) Independent of voltage supply. 2) Values are erased when voltage supply is interrupted. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Powertrain Management/Ignition System/Service Precautions/Technician Safety Information Page 1370 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. Locations Yaw Rate Sensor: Locations G200 - Sensor for transverse acceleration (vehicles with ESP) Page 6384 - Assemble special tool with bonded rubber bushing. - Install bonded rubber bushing and special tool on rear axle. Ensure mark aligns with trailing arm edge. - Install (pull in) bonded rubber bushing by turning spindle. - Check position of bonded rubber bushing after installing. Continue rear axle installation in reverse sequence Tightening torque: Bearing bracket to rear 80 Nm axle (59 ft. lbs.) Use new nuts and bolts! Page 3608 - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor behind catalytic converter must be OK. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor After TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals If specified values are obtained: - End diagnosis and switch ignition off. If specified values are not obtained: - End diagnosis and let engine continue to run at idle. - Check primary voltage. Checking primary voltage - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 5817 Engine Control Module (ECM), Adaptation (Function 10) Alarm Module: Service and Repair Engine Control Module (ECM), Adaptation (Function 10) Replacement Engine Control Module (ECM), Adaptation (function 10) NOTE: - The engine control module is adapted to the immobilizer control module in the instrument cluster. When changing a component it must be readapted. - If an authorized ignition key is not available but the secret number is, new ignition keys must be manufactured and adapted. - The adapting can be interrupted with the "C" button of VAG 1551 Requirements Authorized ignition key available. - Insert old (authorized) key in ignition lock. - Connect VAG 1551, select operating mode 1, "Rapid data transfer". Switch ignition on and enter address word 17, "Instrument cluster". After control module identification has been displayed: Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select function 10, "Adaptation". Indicated on display Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display Adaptation Enter channel number XX - Press button -0- twice to select "Channel O". - Press -Q- button to confirm input. Indicated on display Adaptation Q Erase learned value? - Confirm entry with -Q- button. Indicated on display Adaptation -> Learned values are erased - Press -> button. Indicated on display Rapid data transfer HELP Page 1362 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 130 Door Module: Locations Door Control Module, Rear Left and Rear Right Door control module, rear left and rear right Page 425 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2119 Engine Oil: Application and ID ENGINE OIL: Specifications and Viscosity: Your engine was factory filled with an all season high quality engine oil that has a viscosity grade of SAE 5W-40. You can use this oil over all temperature ranges for normal driving. If you need to add oil between oil changes use any high quality petroleum - or synthetic-based oil with correct specifications. If engine oil viscosity grade SAE 5W-40 is not available, you can also use SAE 5W-30. To assure that the oil you use is of the highest quality required by your car the following terms must appear on the oil container singly or in combination with other designations: Gasoline engine: - VW 502 00 or VW500 00 or VW501 01 - ACEA A2 or ACEA A3 - API Service SJ Diesel engine: - VW 505 00 - ACEA B3 or ACEA B4 - API Service CF4 or API Service CG4 General recommendations: If SAE 5W-40 or 5W-3O viscosity grade oil is not available in your area, be sure to always use a viscosity grade suitable for the climate and seasonal conditions that exist where the vehicle is being operated. Always make sure that the oil meets the quality standards listed above. Engine oil identification symbol: Oils of the proper quality for your vehicle will be identified with a new "starburst" symbol A. The starburst symbol indicates that the oil has been certified by the American Petroleum Institute (API). Another oil identification symbol B could be added to the oil container to help you select the correct oil. 1 - The top portion indicates the oil quality by API designations. 2 - The center portion shows the SAE oil viscosity grade. 3 - The lower portion indicates that the oil has fuel saving capabilities. Note: Page 5896 Alternator Pulley: Service and Repair Generator (GEN) Ribbed Belt Pulley, Replacing Generator (GEN) Ribbed Belt Pulley, Replacing Special tools, testers, measuring instruments and auxiliary items required - VAG 1332 Torque wrench (40 - 200 Nm) - 3310 Socket Removing and installing Page 6482 Tires: Specifications Technical data Wheels, tires Part 1 of 2 Wheels, tires Part 2 of 2 Page 3640 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 5676 Page 4451 Final Drive Fluid: Testing and Inspection Final Drive Oil Level, Checking 4 Speed Automatic 01M Final drive oil level, checking The oil level may be checked with transmission installed The difference between Min. and Max. is 0.1 liters. Excess oil can be drawn off using extraction system V.A.G 1358 A. Checking Remove speedometer drive shaft and clean using a cloth. - Install and remove speedometer drive shaft, check oil level on shaft and, if necessary, correct. Final drive oil level must be between Min./Max. Page 3231 - Eliminate error in wires (see wiring diagram). Page 431 Part 2 Page 4693 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4513 - Test-drive vehicle and inspect transmission for signs of leakage. Page 5385 Electronic Brake Control Module: Diagrams ABS Control Module (w/EDL) Page 5824 2. Disconnect components from the circuit one by one and allow sleep current to stabilize after each elimination. 3. Measure vehicle current consumption and voltage drop across fuse once again. If within normal range, as specified in the table (see Current Consumption Matrix attachment), the component with excessive consumption is identified. 4. Repeat steps above until component is identified causing excessive current draw. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2583 Catalytic Converter: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Page 2551 6. Cable guide - For coolant hoses and wiring harness. 7. 8 Nm 8. Upper coolant hose - To top off radiator. - Check for secure seating. 9. Bracket - For wiring harness. 10. Lower coolant hose - From bottom of radiator. - Check for secure seating. 11. To cylinder block 12. After-Run Coolant Pump -V51- Secured to cylinder block by a bracket. 13. Oil cooler 14. O-ring - Replace. 15. From cylinder block 16. Coolant pipe 17. Sealing plug, 2 Nm 18. Coolant pump - Observe installation position. - Check for ease of movement. - If damaged or leaking replace complete. 19. 20 Nm 20. Belt pulley - For coolant pump. 21. 20 Nm - Use Water Pump Wrench -VAG 1590- to loosen and tighten. 22. 25 Nm 23. Expansion tank - Perform leak test on cooling system with Cooling System Tester -VAG 1274- and Adapter -VAG 1274/8-. - Test pressure: 1.4 to 1.6 bar. 24. Seal - Replace if damaged. 25. Sealing Cap - Check with Cooling System Tester -VAG 1274- and Adapter -VAG 1274/9-. - Pressure relief valve must open at a pressure of 1.5 to 1.6 bar. 26. Seal - Replace. 27. Thermostat housing Page 4574 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 1151 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 5981 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1510 Power Window Switch: Service and Repair Power Window Switches In Passenger's Doors, Remove/Install Power Window Switches In Passenger's Doors, Removing And Installing NOTE: The procedure for removing and installing the - Right front window switch -E41- Left rear window switch -E52- Right rear window switch -E54is essentially the same for all switches. Removing the right front window switch -E41- is illustrated below. Removing - Removing (appropriate) door trim - Disconnect electrical connector. - Bend mounting frame -B- out on the longer switch side -A- and remove switch from mounting frame. Installing - Connect electrical connector. - Insert switch -A- in recess in mounting frame -B- and engage. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Vibration damper Mounting bolt 100 nm + 1/4 turn Page 998 ^ Disconnect wiring harness connector -1- from brake light switch -2-. ^ Remove brake light switch by turning (counterclockwise) and pulling switch out of retainer. Obtain the new brake light switch. Note: DO NOT press new brake switch plunger prior to installation. Pre adjustment of plunger will result in inoperative brake lights or brake lights staying on all the time ^ Grasp brake light switch and brake light switch plunger (black arrow). ^ ^Carefully pull the plunger out to full length. ^ Apply a light coat of lubricant Part No. G052142A2 (obtained locally and considered shop supply) to the end of the plunger (black arrow). Note: Lubricant must be applied to prevent premature wear of brake light switch plunger. Brake light switch can only be installed once! Installing switch a second time may result in an inoperable switch. Leave brake pedal in resting position. DO NOT press or hold up brake pedal during brake light switch installation. ^ Carefully insert brake light switch -2- fully into mounting hole (switch will only fit in the access hole one way), pressing the plunger against the brake pedal to adjust position. Tip: A ratcheting sound indicates the brake light switch plunger is being set in position. Page 4040 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Page 2532 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Engine Controls - DTC's 00545/00638 Stored Engine Control Module: Customer Interest Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 6495 1. Axle shaft ^ For special model "Golf GTI 132 kW" ^ Pulling axle shaft out from wheel hub and pressing in 2. Axle shaft ^ Pulling axle shaft out from wheel hub and pressing in 3. Speed sensor 4. Hex socket head bolt, 10 Nm (89 in lb) 5. Suspension strut 6. Hex bolt ^ Always replace ^ The point on the hex bolt must point in normal direction of travel 7. Tie rod end 8. Self-locking nut ^ 60 Nm (44.2 ft lb) plus an additional 90° - 1/4 turn ^ Never less then 90°! ^ Turning angle tolerance 90 to 120° ^ Always replace 9. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 10. Wheel bearing housing For vehicles: ^ With gasoline engines up to and including 92 kW(123 Hp) ^ With SDI/TDI engine Locations Radiator Cooling Fan Temperature Sensor / Switch: Locations F18 - Coolant Fan Control (FC) thermal switch Page 4843 - Pull off connectors -1- and -2-. - Remove transmission sensor wiring harness -3- from retainer tabs -4- on side of valve body. - Unscrew only bolts marked with an arrow (silver colored) to remove valve body. When removing the valve body, the manual valve remains in the valve body. Secure manual valve so that it cannot fall out. - Remove sealant residue on transmission housing using a scraper. - Remove sealant residue on pan with a rotating brush, e.g. a hand drill with a plastic brush (wear protective glasses). - Clean sealing surface; it must be free of oil and grease. Ensure that there are no remains of sealant or bristles in the valve body cover. Even the slightest contamination can cause malfunctions! Installing valve body Page 4437 Part 2 Page 736 Power Trunk / Liftgate Lock Switch: Service and Repair Micro-Switch, Removing and Installing (Wagon) Micro-switch, Removing And Installing Removing - Removing and installing lock cylinder housing - 2 -. - Release catches - arrow - at micro-switch - 1 -. To do so, press catches downward. - Disengage catches - arrows - of micro-switch - 1 - from lock cylinder housing - 2 -. - Remove micro-switch - 1 - from lock cylinder - 2 -. Installing - Secure wires - 1 - and - 2 - in retaining profile - arrow - of micro-switch - 3 -. System Pressure Fuel Pressure: Specifications With Hose to Regulator Connected approx. 2.5 bar With Hose to Regulator Disconnected approx. 3.0 bar Page 280 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 5585 SUBLETS At -A- Glance For vehicles that, according to your information, cannot be corrected, and one of the codes below best describe the reason, please enter into the system one of the codes indicated, as applicable: Campaign Verification For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding campaign inquiry and verification system; other systems are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as minimize inconvenience to your customers, you are urged to service each vehicle at the scheduled service appointment time, supply a loaner vehicle for the day. Make sure that each vehicle is returned to the customer washed and cleaned inside. In the event the customer waits during the service, do not let them wait longer than specified for the recall repair service in the owner notification letter. Please make every effort to reduce inconvenience to customers. Service Help Dealer Personnel Information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Thank you for your cooperation. Overview This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Page 5691 Owner Letter 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 5675 Owner Letter Page 2589 Indicated on display (1-4 " display fields) Press brake pedal and hold. Note: The engine control unit will increase the engine speed. - Check catalytic converter conversion (amplitude ratio) in field 3: Specification: 0.50 maximum - Let engine run at higher speed until "Cat B1 OK" is displayed in field 4. If the diagnosis is started by the engine control unit, field 4 will jump from "Test OFF" to "Test ON." Note: Diagnosis of the catalytic converter lasts about 100 seconds. Engine Controls - DTC's 00545/00638 Stored Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 4178 Test Step 1 - 2 System Pressure Fuel Pressure: Specifications With Hose to Regulator Connected approx. 2.5 bar With Hose to Regulator Disconnected approx. 3.0 bar Page 4170 Test Step 7 - 15 Page 1336 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 2167 6 - Intake Manifold Lower Section. 7 - Seal. Always replace. 8 - To Intake Hose. For air circulation of fuel injectors. 9 - Bracket. For Secondary Air Injection (AIR) pump motor -V101- and secondary air inlet valve. - Secondary air system. 10 - 25 Nm. 11 - O-ring. Always replace if damaged. - Before installing, moisten with clean engine oil. 12 - Injectors -N30- through -N33-, -N83- and -N84-. Page 3104 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Page 4164 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Service and Repair Traction Control Switch: Service and Repair Removing and installing is the same for all switches and only the emergency flasher switch -E3- is described here. The switch consists of a switch housing and a switch trim with the relevant symbol. The switch trim is clipped onto the switch housing. If the switch trim is released instead of the switch during the removal sequence, the switch trim must be reclipped onto the switch housing after completing the work. The switch must be pulled, together with the connected wiring, out of the instrument panel to separate the connection. It may be necessary to remove the harness connector of the switch on the left of the relevant switch, so that the wiring to the switch can be pulled out sufficiently. Removing switch - Protect instrument panel around the cover with adhesive tape if necessary. - Release switch carefully from instrument panel using blade of knife or screwdriver and remove. - Release harness connectors and remove. Installing switch - Connect harness connector. - Push switch into mounting and engage. - Clip switch trim onto switch housing if necessary. Page 3441 Page 3938 Fuel Pressure: Specifications Residual Pressure After 10 minutes there must be a residual pressure of at least ................................................................................................................................ 2.0 bar. Page 5630 ^ Disconnect connector -1- of Mass Air Flow MAF sensor from air filter tube ^ Remove bolts -2- at air filter -3- and move filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. ^ Remove as much brake fluid as possible from brake fluid reservoir using a brake bleeder bottle. ^ Insert brake pedal depressor VAG 1869/2 or equivalent. ^ Activate brake pedal booster with brake pedal depressor. ^ Connect bleeder bottle hose to bleed screw of left front brake caliper and open bleed screw. ^ Close left front bleed screw. ^ Release ABS control module connector (arrow-1-) and remove (arrow-2-). ^ Place plastic covering under control module and hydraulic unit. Do not use rags. Note: Do not let brake fluid enter electrical connectors. ^ Disconnect brake lines from hydraulic unit to brake master cylinder (arrows) and suspend with wire. ^ Disconnect remaining brake lines from hydraulic unit. ^ Seal brake lines and threaded holes (arrows) using plugs from repair kit, Part No. 1 HO 698 311 A. Page 1301 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4487 Indicated on display 1) appears alternately - Start engine. - Press key 1 for "Rapid data transfer" mode. Indicated on display Press keys O and 2 to select address word "Transmission electronics". Indicated on display Confirm entry with key Q. Indicated on display Press keys O and 8 to select function "Read measured value block". Indicated on display Confirm entry with key Q. Page 6433 - Install coil spring with compressor-VAG 1752/1- on spring perch. NOTE: End of coil spring must lie against stop (arrow). Tightening torque: Nut for upper shock absorber 60 Nm (44 ft. lbs.) Always replace nut! Nut for upper spring plate 60 Nm (44 ft. lbs.) Always replace nut! Continue installation in reverse sequence. Page 856 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temperature Switch Ambient temperature switch -F38- Switches off A/C clutch -N25- at low outside temperatures. - Off at -1 °C (30 °F). - On at +7 °C (45 °F). Page 3254 Engine Speed Sensor: Testing and Inspection With Generic Scan Tool Check Engine Speed (RPM) Sensor Function The Engine Speed (RPM) Sensor -G28- detects engine speed and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test sequence Vehicles with engine code AFP - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Vehicles with engine code BDF - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Continuation for all vehicles Page 2749 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1807 S164 - Fuse -3- (30) in fuse bracket/battery S176 - Fuse -4- (30) In Fuse Bracket/Battery S176 - Fuse -4- (30) in fuse bracket/battery S177 - Fuse -5- (30) In Fuse Bracket/Battery Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2960 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Page 2975 System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 337 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 6124 Part 2 Page 3394 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4134 - Separate connector-arrow- and remove shift lock solenoid -N110- downward. Installing - Join connector -arrow- to shift lock solenoid - Fit solenoid in locking pawl -arrow B-. - Clip shift lock solenoid -N110- into retainer -arrows A-. - Tighten cover with bonded seal to mounting bracket. Note: Ensure the seal remains seated correctly. - Tighten nuts -arrows A- to 10 Nm. Page 5853 Battery: Component Tests and General Diagnostics Visual Check Batteries Without Charge Indicator (magic Eye), Checking Visual check Always perform a visual check of the battery before checking no load voltage, electrolyte specific gravity and load test. Check for: - Cracked battery case and resulting corrosion damage to surrounding area. - Loose, damaged or corroded battery posts and terminals. WARNING! - Ensure that all battery post/terminal connections are securely installed and tightened according to the torque value specified. - Intermittent contact at battery terminals may spark or cause electrical system malfunctions. Electrolyte Level Checking Electrolyte Level, Checking (batteries Without Charge Indicator) Special tools, testers and auxiliary items needed - Commercially available hydrometer Page 3618 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- from Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). - Check wiring for open circuit between test box and 6-pin harness connector (to control module) according to wiring diagram. Terminal -1- + socket 70 - Terminal -2- + socket 71 - Terminal -5- + socket 51 - Terminal -6- + socket 52 - Wire resistance: Max. 1.5 ohms 4 Speed Automatic 01M Torque Converter: Service and Repair 4 Speed Automatic 01M Torque Converter, Draining Torque converter, draining Special tools and equipment - V.A.G 1358 A Oil extractor If the torque converter has become fouled by abrasion or when performing a major overhaul of the transmission, drain the torque converter as follows: - Extract ATF from torque converter using V.A.G 1358 A and probe V.A.G 1358 A/1. Sleeve Bearing From Turbine Shaft Removing sleeve bearing from turbine shaft Place transmission in its installation position on oil pan. Remove torque converter. Page 283 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 1172 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 2-pin harness connector using wiring diagram. Terminal -2- + socket 39 - Wire resistance: Max. 1.5 ohms - Additionally, check wires for short to one another. - Additionally, check wiring for short to battery positive (B+) or Ground (GND). Page 3569 If no malfunctions are found in wire: Vehicles with engine code AFP - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Vehicles with engine code BDF - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Continuation for all vehicles Range A displays resistance values for the temperature range of 0...50 degree C, range B displays resistance values for the temperature range of 50...100 degee C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 3579 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 1029 ^ EXAMPLE of INCORRECTLY installed switch. Internal stop pin (white arrow) is NOT seated fully against outer shell (black arrow). ^ EXAMPLE of CORRECTLY installed switch. Internal stop pin (white arrow) is seated fully against outer shell (black arrow). - Connect brake switch connector. Operate brake pedal to verify proper function, then reinstall lower cover panel. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. 4 Speed Automatic 01M Shift Cable: Adjustments 4 Speed Automatic 01M Selector lever cable, checking and adjusting Checking Shift selector lever into "P" position. - Pry selector lever cable off lever/selector shaft and route so that end is free to move. Note: Do not bend or kink the selector lever cable. - Move selector lever from "P" to "1". - Check front protective sleeve on selector lever cable for damage, if necessary replace cable. - Shift selector lever into "P" position. Selector lever mechanism and selector lever cable must move freely, if necessary replace selector lever cable or service selector lever mechanism. - Press on selector lever cable. Adjusting Shift selector lever into "P" position. - Loosen bolt -2- at selector lever cable front ball mounting -1-. - Bring selector shaft lever in position "P" on transmission. Locking lever must engage in park lock wheel, both front wheels are blocked (cannot be turned together in same direction). Page 3871 Texaco Petro-Canada Sunoco-Canada - For the fast removal of existing carbon deposits from injectors, combustion chambers and intake valves (intake valves apply to MPI engines only) gasoline additive G00170003 can be used. Mix additive directly with gasoline in fuel tank following mix ratio described on additive container. (example 20 ml per 10 liters of gasoline, 150 ml per 20 gallons of gasoline). Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 6435 - Pull connector -1- off speed sensor. - Unclip speed sensor wiring from retainer. - Remove bolts -1- with vehicle standing on its wheels (raise vehicle until bolts are accessible). - Raise vehicle to relieve pressure on coil spring. - Remove spring. Installing spring - Ensure spacer bushing (zinc) is not damaged. Replace if necessary. - Install spring together with spring seat. - Loosen spring and remove spring compressor. Observe installation position! Page 3486 - Switch ignition off. NOTE: If the basic setting of the control module is interrupted, the cause could be one of the following: - Throttle valve cannot reach the mechanical stop because of contamination (e.g. oil deposits or an incorrectly adjusted accelerator pedal cable). - Battery voltage too low. - Throttle valve control module or wiring is faulty. Refer to "Throttle Valve Control Module, Checking", See: Electronic Throttle Control Module/Testing and Inspection After an interruption the fault "17973" is stored in DTC memory. When the ignition is switched on again, the basic setting is automatically performed again. - End basic setting by pressing -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 1591 Idle Speed: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Camber, Adjusting, Front Wheel Alignment: Service and Repair Camber, Adjusting, Front Wheel Front wheel camber, adjusting Camber cannot be adjusted If vehicle is out of specification, check trim height and balance if necessary By adjusting sub-frame it is possible to bring camber within tolerance. - Loosen bolts -1- and -2-. - Move sub-frame to equalize camber on both sides. - Check caster; caster can also change when moving sub-frame. NOTE: Always replace sub-frame bolts (one at a time) when making this type of adjustment. Tightening torque Support to body 100 Nm (74 ft. lbs.) + turn 90° Bolt position -1- Use new bolts! Support to body 100 Nm (74 ft. lbs.) + turn 90° Bolt position -2- Use new bolts! Page 154 Part 2 Page 1923 Axle Nut: Tools and Equipment VW/Audi Axle Nut Set AST tool# 6500 Page 4090 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. 4 Speed Automatic 01M Shift Interlock Solenoid: Service and Repair 4 Speed Automatic 01M Shift lock solenoid -N110-, removing and installing Removing Obtain radio code on vehicles with coded radio. - Disconnect battery Ground strap. - Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7 and remove. Note contact spring for selector lever position display! - Remove locking segment (2 bolts). - Place selector lever in position "1". - Remove retaining bracket -8- (2 nuts). - Remove solenoid securing bolts -9- (Qty. 2) - Remove front selector mechanism securing nuts (Qty. 2). - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. Note: Do not bend or kink the selector lever cable. Page 5882 Battery: Service and Repair Battery Charging Battery, Charging WARNING! Danger of explosion! - Batteries produce explosive gasses while being charged. - Keep open flames and sparks away and DO NOT smoke near batteries. - The battery charger MUST be turned off when connecting or disconnecting the cables at the battery - Battery cell caps must NOT be removed while charging. - "Boosting" a sulfated battery a high charging rate can cause an explosion. - Ensure that battery is charged in a well ventilated area. - Precision tools must not be kept in the same room where batteries are being charged. Tools may corrode due to chemical reaction. CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Special tools, testers and auxiliary items needed - Battery charger: Christie Automotive 400 QDD or equivalent. Battery charger, connecting NOTE: - Before charging, battery must have a minimum temperature of 10 °C (50 °F) - Always follow the battery charger operating instructions - After charging, confirm battery no load voltage and electrolyte specific gravity before reuse in vehicle. - Switch off battery charger. - Switch off ignition. - Disconnect negative GND terminal from battery negative (-) pole - Disconnect positive B+ terminal from battery positive (+) pole - Connect battery charger to battery, positive to positive (+), negative to negative (-). - Adjust charging rate according to battery capacity (refer to charger instructions). - Switch on battery charger. WARNING! If battery begins gassing (boiling) violently when charging, REDUCE charging rate immediately. Charging totally discharged batteries Batteries that have not been used for long periods of time begin to self discharge (e.g. vehicles in storage). Under these conditions, the battery begins to sulfate and the surface area of the battery plates hardens. A battery is considered to be totally discharged if the no load voltage is below 11.6 volts. On totally discharged batteries, the electrolyte (sulfuric acid/water mixture) is almost all water. When these batteries are exposed to freezing temperatures, permanent damage to the battery plates (and housing) results. If a totally discharged battery is charged quickly ("quick charged" or "boost charged"), only a surface charge is accepted (if at all). The battery may even test OK immediately after charging. However, in this case the sulfating process continues inside the battery. Once a battery begins to sulfate, it's ability to further accept a routine charge (from the Generator) and provide adequate load and reserve performance will diminish until the battery malfunctions. Totally discharged batteries must only be slow charged and re-tested as described below: - Apply a maximum charge current that is no more than 10% of battery capacity, e.g.: for a 6 Ah battery, max. charge current = 6 amps. - Charge a totally discharged battery for a minimum of 24 hours. CAUTION! Never "quick charge" a totally discharged battery. Effective charging will not take place, despite what appears to be a sufficient voltage applied. Batteries loaded in this manner may be incorrectly evaluated as OK and battery damage may result. Page 6444 Special tools, testers and auxiliary items required ^ Thrust pad VW447 1 ^ Pressing appliance VW459/2 ^ Thrust pad 40 - 105 ^ Box wrench SW 32 3252 A ^ Assembly tool 3253 ^ Collar for wheel bearing inner race 3423 Page 3846 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the idle speed is not obtained: - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. See: Computers and Control Systems/Engine Control Module/Testing and Inspection - Carry out road test. Observe the valid safety precautions when carrying out a road test. See: Service Precautions/Technician Safety Information - Check DTC memory again. - Repeat idling check. If the specified values are not obtained again: - Check throttle valve control module. - Check intake air system for unmetered air. - Check operating condition of engine. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Operating Conditions, Checking - Check signals from/to air conditioner. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/A/C Compressor Signal, Checking Page 696 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5296 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1530 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Page 6420 - Remove bolts -1- and -2- and remove pendulum support. - Remove steering gear bolts -5-. - Remove stabilizer bar link nut -7 - On TDI engines, remove exhaust system bolts -6-. - Place transmission jack VAG 1383A with 1359/2 under sub-frame. - Remove bolts -3- and -4- for sub-frame. - Lower sub-frame using engine/transmission Jack VAG 1383 A. Installing Before installing sub-frame bolts, position steering gear on sub-frame and install bolts. Threaded sleeve -1- must seat in subframe hole. Continue installation in reverse sequence. Check steering wheel position during test drive. - Check front wheel toe if steering wheel is not positioned straight ahead. Tightening torque: Ball joint to control arm 20 Nm (15 ft. lbs.) + 90° Use new bolts! Pendulum support to subframe M 10 x 70 50 Nm (37 ft. lbs.) M 10 x 30 50 Nm (37 ft. lbs.) Steering gear to sub-frame 20 Nm (15 ft. lbs.) + 90° Use new bolts! Coupling rod to stabilizer bar 30 Nm (22 ft. lbs.) Page 6131 Fuse: Application and ID Fuse Arrangements In Fuse Bracket/Battery Fuse arrangements in fuse bracket/battery Page 2168 - Air shrouded. - Check. 13 - Retaining clip. Check securely seated. 14 - Vacuum connection. To T-piece connection non-return valve / intake manifold upper section. 15 - Fuel pressure regulator. Check. Page 556 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Checking voltage supply terminal 30 - Measure supply voltage between test box sockets 1 + 62 using multimeter and adapter cables from VW1594: Specified value: at least 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from battery (B+) voltage, the readiness code must be generated again. Checking voltage supply terminal 15 - Measure supply voltage between test box sockets 2 + 3 using multimeter and auxiliary cables from VW1594. - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Voltage Supply For Engine Control Module (ECM), Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 5856 - Commercially available hydrometer WARNING! - Refer to Warnings and Safety Measures. - If electrolyte level is too high, electrolyte (sulfuric acid/water mixture) may leak out and damage the surrounding area, i.e.: plenum and engine compartment - Excess electrolyte MUST be extracted using a hydrometer - Dispose of electrolyte (sulfuric acid) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal - Remove cell caps from cells with excess electrolyte. - Extract excess electrolyte using hydrometer until electrolyte level is lowered to internal level indicator -1- or external maximum marking. CAUTION! Use use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. Only use genuine cell caps of the same construction if lost or damaged. All cell caps must be equipped with an O-ring seal. Electrolyte Level, Checking Special tools and equipment Page 336 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) EPC Warning Lamp Operation Malfunction Indicator Lamp: Description and Operation EPC Warning Lamp Operation Electronic Power Control (EPC) Warning Lamp (Malfunction Indicator Lamp For Electronic Accelerator [E-Gas]) In Instrument Cluster, Significance The EPC warning lamp is the Malfunction Indicator Lamp for the electronic accelerator (E-gas) system. Location of EPC warning lamp The engine control module checks all the important functions of the electronic accelerator system after switching the ignition on. The instrument cluster switches the EPC warning lamp on for about 1 second during the test of this component. If a malfunction is recognized during the test, the lamp will light continuously. If malfunctions are recognized in the electronic accelerator system (EGas) when the engine is in operation, the engine control module will send a message to the instrument cluster, and the instrument cluster will switch on the EPC warning lamp (these malfunctions are indicated in the DTC table). Simultaneously, an entry is made in the engine control module DTC memory. Page 1472 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 3476 - Eliminate error in wires (see wiring diagram). 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 6211 Specifications for front axle with front wheel drive 5) Camber corrections are not possible. Corrections are possible by moving the sub-frame slightly. Adjust approx 10' to 15' Specifications for rear axle, vehicles with front wheel drive Overview of work procedure for measuring vehicle The following work sequence of steps must be adhered to! - Check front axle camber and adjust if necessary. Adjusting camber, Refer to Alignment, Service and Repair, Camber. - Check rear axle camber. Camber is not adjustable, Notes, Refer to Alignment, Service and Repair,Camber on rear axle, adjusting - Check rear axle toe and adjust if necessary Refer to Alignment, Service and Repair,Toe on Rear axle, vehicles with front Wheel drive, adjusting Vehicles with front wheel drive The rear axle toe is not adjustable. Notes, Alignment, Service and Repair - Check front axle toe and adjust if necessary. Interior - Steering Wheel Leather Wrap Coming Loose Steering Wheel: All Technical Service Bulletins Interior - Steering Wheel Leather Wrap Coming Loose Condition Steering Wheel, Repairing Leather Wrap Steering wheel leather wrap loose. 69 06 08 Nov.16, 2006, 2010641, Supersedes Technical Bulletin Group 69 number 04-04 dated October 19, 2004 due to inclusion into ElsaWeb. Technical Background Leather wrapping coming loose at inner spokes due to poor adhesion. Production Solution No production change required. Service For Golf, GTI, Jetta, New Jetta, New Beetle, New Beetle Convertible, Passat, Passat Wagon and Touareg vehicles: - Remove steering wheel.See Repair Manual, Body Interior, Repair Group 69 For Cabrio vehicles: - Remove steering wheel.See Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48. - Cover portion of steering wheel not being serviced. Perform the following procedure to one steering wheel spoke at a time. - Gently pull back loose leather as far as possible -arrow-. - Completely cover exposed substrate with a generous amount of 3M® Super Weatherstrip Adhesive (Part No.08008). Tip: Do not allow adhesive to dry. - Using firm pressure, roll leather back in place. - Smooth leather until stress marks disappear. - Work leather at edges until properly located and visually acceptable. Removal and Installation Timing Chain: Service and Repair Removal and Installation Removal Timing Chain Removal Required Special Tools - 3268 Camshaft Guide Tool Preliminary Components: - Disconnect Battery. - Remove intake air box, please refer to: Vehicle/ Powertrain Management/ Fuel and Air Delivery/ Air Cleaner Housing/ Service and Repair/ See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair. - Remove Throttle Body. - Remove Ignition Coil Packs. - Remove spark plugs. - Remove Valve Cover, please refer to: Vehicle/ Engine/ Cylinder Head Assembly/ Valve Cover/ Service and Repair/ See: Cylinder Head Assembly/Valve Cover/Service and Repair. - Remove transmission, for Automatic Transmission please refer to: Vehicle/ Transmission and Drivetrain/ Automatic Transmission/Transaxle/ Service and Repair See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair, for Manual Transmission please refer to: Vehicle/ Transmission and Drivetrain/ Manual Transmission/Transaxle/ Service and Repair See: Transmission and Drivetrain/Manual Transmission/Transaxle/Service and Repair. NOTE: Support engine - Remove upper intake manifold, please refer to: Vehicle/ Engine/ Intake Manifold/ Service and Repair/ See: Intake Manifold/Service and Repair. - Remove Clutch, please refer to: Vehicle/ Transmission and Drivetrain/ Clutch/ Service and Repair/ See: Transmission and Drivetrain/Clutch/Service and Repair. - Remove Flywheel. Removal Page 6338 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 857 Ambient Temperature Sensor / Switch HVAC: Description and Operation Outside Temperature Sensor Outside temperature sensor -G17- (Item #11 in image) Function: Temperature sensor controls temperature flap and fresh air blower, depending on temperature. In the event of malfunction: fresh air intake duct temperature sensor -G89- takes over. If both sensors are malfunctioning, operation continues assuming a value of +10 °C (50 °F). Air recirculation not possible. A/C control head -E87- indicates: "---" Locations Radiator Cooling Fan Motor Relay: Locations The coolant/condenser fan(s) for this vehicle is/are controlled by the following and does not use relays: Coolant Fan Control (FC) Thermal Switch F18. See: Radiator Cooling Fan Temperature Sensor / Switch/Locations - Coolant Fan Control (FC) Control Module J293. See: Radiator Cooling Fan Control Module/Locations - A/C Pressure Switch F129 (via J293), if equipped. See: A/C Pressure Sensor/Switch - Cooling Fan/Locations - High Pressure Sensor G65 (via J293), if equipped. See: A/C Pressure Sensor/Switch - Cooling Fan/Locations Page 5469 ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting wheel speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert wheel speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor to speed sensor wiring. Wheel speed sensor on rear axle (drum brakes), removing and installing Removing ^ Raise vehicle. ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect speed sensor to speed sensor wiring. ABS wheel speed sensor wiring to rear axle, removing and installing Required special tools Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (Automatic Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (Automatic transmission) Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 5836 Part 1 Page 1992 Connecting Rod: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 2882 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 1285 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 5587 Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing Note: Tire and wheel removal is not necessary Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening Note: The label showing supplier code is upside down in vehicle ^ If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C ^ If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation ^ Obtain radio code and record radio preset stations ^ Turn Ignition Switch to "OFF" position ^ Open hood and place fender cover in position ^ Disconnect the ground cable (GDN) from the negative (-) battery terminal <-- Disconnect electrical connector -1- from mass air flow sensor -2<-- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) Page 6504 Wheel Bearing: Service and Repair Rear Wheel Bearings, Servicing Wheel bearings, servicing Wheel bearings, vehicles with front wheel drive, servicing Note: The descriptions and illustrations are for vehicles with disc brakes. - Wheel fittings for vehicles with drum brakes is the same. - All tightening torques and notes are therefore valid for vehicles with drum brakes. 1. Phillips-head screw 2. Brake disc 3. Dust cap - Always replace A perfect seal is only achieved using a new dust cap. Only then is an optimum function and long service life guaranteed. 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace 5. Wheel hub with wheel bearings The wheel bearing and wheel hub are installed together in housing. This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible! 6. Axle beam Page 3131 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. Page 566 Select function XX NOTE: The next time the ignition is switched "on" the identification of the engine control module is read by the immobilizer control module and stored. With Manufacturer's Scan Tool Intake Air Temperature Sensor: Testing and Inspection With Manufacturer's Scan Tool Intake Air Temperature Sensor -G42- Checking NOTE: The Intake Air Temperature (IAT) sensor -G42- is a part of the Mass Air Flow (MAF) sensor -G70- and cannot be replaced separately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram - VAG1921 hose clip pliers - Chilling spray (commercially available) Test sequence NOTE: Only gold plated contacts must be used to repair The contacts in the intake air temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read intake air temperature value in display field 4. Page 1443 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 5996 Fuse arrangements in fuse holder, instrument panel left Fuse Arrangements In Fuse Bracket/Battery Page 3142 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 2536 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 5140 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection Checking hydraulic lifters Special tools, equipment, test and inspection devices; required accessories: Feeler gauge - Wooden or plastic wedge Test procedure Notes: Valve lifters must be replaced as units (they cannot be adjusted or repaired). - Intermittent valve noises during engine start-up are normal. - Start engine and let it run until radiator fan has turned on once. - Increase engine speed to approximately 2500 rpm for 2 minutes. If the hydraulic lifters continue to make noise, find the faulty lifter as follows: Remove cylinder head cover. - Turn camshaft at oscillating damper fastening screw clockwise until valve lifter cams being tested are in upper position. - Determine clearance between cams and valve lifters. - If clearance is greater than 0.2 mm, replace valve lifters. If clearance is less then 0.1 mm or no clearance is determined, continue test as follows: - Push valve lifters downward with a wooden or plastic wedge. If you can feel unrestricted motion of more than 0.2 mm until valve opens, replace lifters. Note: After installing new valve lifters, do not start the engine until after about 30 minutes. Hydraulic balancing elements must become properly seated (otherwise, valves will make contact with the piston). Page 5561 Remove piston seal using wedge 3409. Note: When removing piston seal make sure that the cylinder bore is not damaged. Installing ^ Lubricate piston, piston seal and cylinder bore lightly with assembly lubricant G 052 150 A2 ^ Install new piston seal in caliper. ^ Place protective seal with outer sealing lip on piston. ^ Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409. ^ Press piston into brake caliper housing using piston resetting tool. The protective seal outer sealing lip must slip into the piston groove. Page 6008 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1980 Variable Valve Timing Actuator: Testing and Inspection With Generic Scan Tool Valves For Camshaft Adjustment (Vehicles With Engine Code BDF), Checking Function The camshaft adjustment is load-and RPM dependent. The electrical valves for camshaft adjustment switch oil pressure onto camshaft adjusters (mechanical adjustment mechanisms), which then adjust the camshafts. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of the Valve -1- for camshaft adjustment -N205-and Camshaft Adjustment Valve 1 (exhaust) -N318- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P-or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Disconnect 2-pin harness connector to the respective valve for camshaft adjustment: 1 - Valve -1- for camshaft adjustment -N2052 - Camshaft Adjustment Valve 1 (exhaust) -N318NOTE: Before disconnecting harness connectors, mark allocation to component. Page 2708 - Read off supply voltage for Engine Control Module (ECM) in display field 2. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Evaluating display group 4, display field 2 - control module voltage supply Page 3475 - Perform resistance measurement again between test box sockets 77 + 79: Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Terminal Resistance For CAN-Bus, Checking Function The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm If specified value is obtained (wires have no shorts): Engine - Rattling Noise On Start Up (Normal Condition) Variable Valve Timing Actuator: Technical Service Bulletins Engine - Rattling Noise On Start Up (Normal Condition) Condition Camshaft Chain Tensioner(s) or Camshaft Adjuster(s), Rattle or Knocking Noise 15 06 01 Oct. 24, 2006 2012988 Technical Background The camshaft adjustment is hydraulically actuated and controlled by the engine oil pressure. If the vehicle has been sitting, with the engine turned off for a period of time, the oil accumulation inside the camshaft adjusters partially bleeds off and the oil flows back into the oil sump. To ensure an efficient camshaft adjustment after an engine cold start, the oil pressure inside the camshaft adjusters must be built up as quickly as possible. During this time a slight rattle or knocking noise may be audible. This noise is normal at engine start and will last until the oil pressure is fully reinstated. Production Solution No production change required. Service DO NOT replace the Camshaft Tensioner(s) or Camshaft Adjuster(s) for the noise concern as described above. Tip: Replacing the Camshaft Tensioner(s) or Camshaft Adjuster(s) will not eliminate this noise. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Always see ETKA for the latest part(s) information. Page 3280 - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Page 4577 Test Step 3 - 6 Page 5171 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide Page 1348 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 3244 - Reduced Transmission life. Capacity Specifications Fluid - A/T: Capacity Specifications 4 Speed 01M Planetary gearbox fluid Capacity ......................................................................................................... ........................................................................ 5.3L (filled for life, no change) Final drive Initial filling ......................................................................................................................... .......................................................................................... 0.75L Oil change ...................................... ................................................................................................................................................ Filled for life (no change) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... .................................................... 7.0L (filled for life) 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 5848 Battery: Application and ID Batteries With Central Gas Venting Batteries With Central Gas Venting Batteries with two different styles of central gas venting are installed: - Batteries with central gas vent hose - Batteries without central gas vent hose CAUTION! - Only new generation batteries with central gas venting are to be installed! - For proper function of central venting and flame trap, check vent hose (where applicable) for proper installation. Vent hose must NOT be disconnected or pinched. - Only the use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. - Only use genuine VW cell caps of the same construction if lost or damaged. - Caps must be fitted with an O-ring seal. Page 1221 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Powertrain Management/Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 3576 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Ignition Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Engine Controls - DTC's 00545/00638 Stored Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 4920 Constant Velocity Joint: Service and Repair Rear Axle, Removing and Installing Special tools and equipment - VAG 1383A transmission jack - VAG 1869 Brake filling and bleeding unit Removing NOTE: Do not remove bearing bracket to remove rear axle - Remove bolts -1- with vehicle standing on its wheels (raise vehicle until bolts are accessible). Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 294 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 2358 ^ Remove passenger side sill panel trim. ^ Lift rear seat and remove cover for fuel pump/fuel gauge sensor. Engine overlay harness, preparation Prior to installing the engine overlay harness, prepare the harness as follows: ^ Locate single wire portion of engine overlay harness. ^ Cut terminal and wire approx. 5cm (2 in.) from terminal end (SAVE for reinstallation at a later point in procedure). Vehicles without Climatronic: ^ Cut ambient temperature sensor wire and tape back to harness (see above - Unused wiring, taping back to harness). ^ Locate two wire portion of engine overlay harness. ^ Locate guide tube from kit, cut one end at sharp angle. ^ Insert one wire from two wire portion of engine overlay harness into guide tube and tape second wire over guide tube using vinyl tape. Engine overlay harness, installing Page 6354 Indicated on display (select function): Rapid data transfer HELP Select function XX - Press buttons -0- and -2- to select "Check Diagnostic Trouble Code (DTC) memory" function 02. Indicated on display: Rapid data transfer Q 02 - check DTC memory - Press -Q- button to confirm input. The number of stored malfunctions appears in the display. X DTC recognized! -> The number of stored DTCs or "No DTCs recognized" appears in the display and are printed out one after another. - When the last DTC has been displayed and printed out, correct malfunctions as described in DTC table. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/VAG Code Charts/Multi-Function Steering Wheel/VAG Codes If "No DTC recognized" is displayed, the program will return to the initial position after pressing -> button. No DTC recognized -> Indicated on display (select function): Rapid data transfer HELP Select function XX If display not indicated as shown: See Scan tool operating instructions - End Output (function 06). - Switch off ignition and disconnect Data Link Connector (DLC). NOTE: If DTCs were recognized, follow the sequence below: - 1. Correct malfunction. - 2. Erase Diagnostic Trouble Code (DTC) memory (function 05). - 3. Check Diagnostic Trouble Code (DTC) memory (function 02). Without Manufacturer Scan Tool The manufacturer does not provide a procedure for reading diagnostic trouble codes without a scan tool. Spark Plug Pliers - AST Tool # H 1849 Spark Plug: Tools and Equipment Spark Plug Pliers - AST Tool # H 1849 Spark Plug Pliers AST tool# H 1849 Used for the R and R of spark plug connectors and specifically for those with anti-heat terminals. These Pliers are applicable to Mercedes models 190 E and 300 E, and VW/Audi. - Spark Plug Pliers - Applicable to Mercedes, VW and Audi - Steel Construction and Easy-Grip Handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5642 - Install VAG 1310/26 at each port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". NOTE: Once the brake pressure leak test has been completed, the hydraulic brake system MUST be purged of any entrained air. See Repair Manual Group 47, Brake System Bleeding. Warranty Information only. Required Parts and Tools No Special Parts required. Always see ETKA for the latest part(s) information. Page 700 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3147 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 6096 Part 1 Page 5429 Page 1257 Display Group 032 Initiating learning process: Control module in Basic Setting scan tool function 04. Learning prerequisites for idle speed: - Idle speed - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C Locations Condenser Fan Motor Relay: Locations The coolant/condenser fan(s) for this vehicle is/are controlled by the following and does not use relays: Coolant Fan Control (FC) Thermal Switch F18. See: Engine, Cooling and Exhaust/Cooling System/Engine - Coolant Temperature Sensor/Switch/Radiator Cooling Fan Temperature Sensor / Switch/Locations - Coolant Fan Control (FC) Control Module J293. See: Relays and Modules - Cooling System/Radiator Cooling Fan Control Module/Locations - A/C Pressure Switch F129 (via J293), if equipped. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations - High Pressure Sensor G65 (via J293), if equipped. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Description of On-Board Diagnostics General Information From m.y. 2000 >, instrument clusters are integrated into the "Powertrain" CAN Data Bus network (may also be know as "CAN-Bus" or "Data-Bus"). The Data Bus On Board Diagnostic (OBD) interface -J533- (which is integrated into the instrument cluster) enables data to be exchanged between the various CAN-Bus networks and the Data Link Connector (DLC) "K-wire". The Data Bus On Board Diagnostic (OBD) interface -J533- has specific On Board Diagnostic (OBD) capabilities via address word 19 "Gateway", and must always be coded separately from the instrument cluster. See: Programming and Relearning Connecting VAG 1551 Special tools and equipment - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable Page 2898 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 876 Cabin Temperature Sensor / Switch: Description and Operation Instrument panel temperature sensor -G56- with interior temperature sensor fan -V42- Function: Temperature sensor controls temperature flap and fresh air blower depending on temperature. - In event of -G56- malfunction, operation continues assuming value of +24 °C (75 °F) Page 568 Wire Terminal Extractor used for ECU and ABS harnesses on 1998-2005 Jetta and Passat. The blade of the H 4673-9 has a width of 1mm. - Made in Germany - Easy to Use Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 311 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 3800 Canister Purge Control Valve: Testing and Inspection With Generic Scan Tool Evaporative Emission (EVAP) Canister Purge Regulator Valve, Checking Solenoid valve is closed when no voltage is present. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80must be OK. - Ignition switched off. Test sequence - Disconnect 2-pin connector from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (arrow). - Measure resistance between terminals of solenoid valve. Specified value: 22.0...30.0 Ohms If specified value is not obtained: Page 2981 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1733 - The engine/transmission angle has changed and therefore the lower edge of the oil fill hole -1- is located below the new oil level -2-. - To properly check oil level, transmission must be drained completely and re-filled. Tip: The transmission housing must be cleaned and dried before servicing. Shift fork pins must be removed in order to drain transmission. Selector shaft, securing ^ Remove air cleaner housing. ^ Remove sound insulation. ^ Clean and dry transmission. ^ Secure selector shaft so that the position of shift fork pins can not move: ^ Press selector shaft down arrow -1^ While selector shaft is held in down position, turn bracket -A- upward (clockwise) in direction of arrow -2- and press inward until the bracket latches in selector shaft. Tip: Use a clean 3.0L container with graduated markings to catch draining oil Transmission, draining Page 281 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 1561 ^ Axle components have been damaged or replaced (in table) Requirements ^ Vehicle at curb weight ^ Fuel tank full ^ Spare wheel and vehicle tools are stowed at correct locations ^ Fluid reservoir for windshield/headlight washer system full. ^ Tire tread depth on each axle should differ no more than 2 mm (0.079 in.). ^ Tires inflated to correct pressure ^ Vehicle aligned, suspension bounced and rocked several times ^ Suspension, steering and linkage checked for wear and damage. ^ Test equipment properly adjusted and attached to vehicle. ^ Do not check vehicle alignment before vehicle has completed (1000 to 2000 km (600 to 1200 miles), to allow coil springs to settle. ^ Sliding plates and turntables (alignment equip.) must not touch an end stop when checking wheel alignment. ^ Adhere to alignment manufactures instructions ^ Check and calibrate alignment equipment once a year. ^ Treat alignment equipment with care. ^ Maximum wheel run-out must be compensated. Otherwise test results will not be correct. ^ Correct toe-in adjustment is not possible without wheel run-out compensation. NOTE: Carefully follow alignment manufacturer's instructions. - Install brake pedal support. - Compensate for wheel run-out - Lower vehicle and bounce Alignment, overview Work sequence must be followed! 1. Adjust camber 2. Check rear axle camber. Camber is not adjustable. 3. Check toe at rear axle, adjust if necessary Page 488 If no malfunctions are found in wires: - Check voltage supply of Engine Control Module (ECM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Control Module (ECM) Voltage Supply, Checking - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes With Manufacturer's Scan Tool Throttle Valve Control Module, Checking Components of the throttle valve control module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1 - for for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for for throttle drive (power accelerator actuation) -G188NOTE: - If the throttle valve control module is replaced, the new control module must be matched to the Engine Control Module (ECM). Refer to "Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation", See: Engine Control Module/Testing and Inspection - On vehicles with an automatic transmission, the Transmission Control Module (TCM) must also be adapted. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Throttle valve not damaged or dirty. - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3 NOTE: Only gold plated contacts can be used to repair the contacts in the connector for the throttle valve control module. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-1-6- and -2- to input display group number 62 (062) and press -Q- button to confirm input. - Check angle sensor -1- for for throttle drive (power accelerator actuation) -G187- on idle speed stop in display field 1. - Check angle sensor -2- for for throttle drive (power accelerator actuation) -G188- on idle speed stop in display field 2. Page 4750 Torque converter with sleeve bearing in the turbine shaft of the transmission (arrow). New torque converter with integrated needle bearing. A sleeve bearing (arrow) may not be installed in the turbine shaft of the transmission with this type. Remove if necessary. Page 5222 Control Module: Locations J217 - Transmission Control Module (TCM) Service and Repair Exhaust Pipe/Muffler Hanger: Service and Repair For further information regarding this component please refer to Exhaust Systems; Service and Repair. Page 1473 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 229 Sunroof / Moonroof Module: Locations J245 - Power Sunroof Control Module Page 3951 Fuel Pump Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements With Manufacturer's Scan Tool Clutch Switch: Testing and Inspection With Manufacturer's Scan Tool Clutch Pedal Switch (Clutch Vacuum Vent Valve Switch -F36-) Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -6- and -6- to input display group number 66 (066) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 06 -> 1234 - Observe display in display field 2 (2nd digit from left). Specified value: x 0 x x - Depress clutch pedal fully and observe display in display field 2. Specified value: x 1 x x - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 4312 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 5945 ^ Verify remote has not lost synchronization. Tip: DTC 00956, No or Incorrect Basic Settings/Adaptation is a direct result of lost synchronization. Additionally, loss of only 1 remote's functionality can be a result of DTC 00956. NOTE: Synchronization is not a warrantable concern. Synchronization Procedure Model(s) Procedure (A5) Jetta, GTI/Rabbit/R32, Eos, - Switch ON ignition with spare key. Tiguan, Jetta Sport Wagen - Unlock driver door manually by inserting main key in driver door lock cylinder. - Press unlock button once on remote. - Remove spare key from ignition lock cylinder. - Close driver door and verify remote functionality. (B6) Passat Sedan, Wagon, & CC Tip: Care must be taken when removing cover from door handle to expose lock cylinder. - Unlock driver door manually with emergency key (spare). - Switch ON ignition with main key. Touareg & Phaeton - Unlock driver side door manually using door lock cylinder. - Switch ON ignition. (B5) Passat, Passat Wagon - Press lock or unlock button (ONE TIME) for one second. (A4)Golf/Jetta (including Wagon) - Vehicle remains locked. Euro Van - Control unit recognizes only one key code via the master key. City Golf/Jetta - Lock or unlock vehicle with MASTER KEY. New Beetle/New Beetle Convertible - Procedure is complete. If remote is still inoperative, perform the following: ^ Remove battery from remote; see Repair Manual Group 57 - Front doors, Central locking system, Central locking system, in ElsaWeb. ^ Perform a capacitive discharge by pressing down for 5 seconds any button on remote with battery removed. ^ Install new battery and reassemble remote in reverse order. Tip: Observe polarity of battery when installing. The positive terminal is marked in the remote housing and on battery. Verify operation of remote. If remote remains Inoperative, perform ALL of the following: ^ Remove new battery and verify surface voltage is at least 3.0 V ^ Perform an additional capacitive discharge by pressing down any button on remote for 5 seconds while battery is removed. This will erase the battery memory of the remote. ^ Reinstall new battery. Reassemble remote in reverse order. Verify red LED is illuminating when a button is pressed. Page 547 Engine Control Module: Application and ID Control Module Identification and Equipment Control Module Identification The control module version is displayed when the VAG1551 Scan Tool (ST), the VAG1552 mobile scan tool or the VAS5051 vehicle diagnostic, testing and information system is connected and "Engine Electronics" address word 01 is selected See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Manufacturer's Scan Tool/Connecting VAG 1551 Scan Tool Technical data Engine code AFP System designation Motronic ME7.1 Exhaust emissions conform to: OBD II On Board Diagnostic (OBD) yes Output Diagnostic Test Mode yes Operating mode of data transfer to VAG1551/1552 Rapid data transfer DTC memory Non-volatile memory 1) Readiness Code Memory Volatile memory 2) Heated Oxygen Sensors (HO2S) 2 sensors Knock control 2 knock sensors Twin-path intake manifold yes Variable valve timing no Charge pressure control no Secondary Air Injection (AIR) system yes 1) Independent of voltage supply. 2) Values are erased when voltage supply is interrupted. Page 1752 Ag-Ig Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1527 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Diagram 70/3 IMPORTANT NOTE: Page 201 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Locations Radiator Cooling Fan Motor Relay: Locations The coolant/condenser fan(s) for this vehicle is/are controlled by the following and does not use relays: Coolant Fan Control (FC) Thermal Switch F18. See: Engine, Cooling and Exhaust/Cooling System/Engine - Coolant Temperature Sensor/Switch/Radiator Cooling Fan Temperature Sensor / Switch/Locations - Coolant Fan Control (FC) Control Module J293. See: Radiator Cooling Fan Control Module/Locations - A/C Pressure Switch F129 (via J293), if equipped. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations - High Pressure Sensor G65 (via J293), if equipped. See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations Page 3508 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 2390 A/C Pressure Sensor/Switch - Cooling Fan: Locations High Pressure Sensor G65 G65 High Pressure Sensor in engine compartment, right rear, in refrigerant line Page 5681 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 1423 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. With Manufacturer's Scan Tool Engine Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Engine Speed (RPM) Sensor -G28-, Checking The engine speed (RPM) sensor -G28- is a speed and reference mark sensor. The engine will not start if there is no speed signal. If the speed signal fails when the engine is running, it will cause the engine to stall immediately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test sequence - Disconnect grey 3-pin harness connector (arrow) from engine speed sensor. - Measure sensor resistance between terminals 2 + 3 of harness connector to sensor. Specified value: 480-1000 ohms - Check sensor for short between terminals 1 + 2 as well as -1- + -3-. Specified value: infinity ohms If the specified values are not obtained: - Replace engine speed (RPM) sensor -G28-, item 25. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 4834 - Marking see Fig. 6 - Installing seal -item 10 12. Bolt, 10 Nm 13. O-ring - Always replace 14. Conductor strip - With cable transition piece and connector - Can be removed and installed with transmission installed 15. Retaining bracket - For the conductor strip connector installing see Fig. 11 16. Bolt, 20 Nm 17. Plug for solenoid valves - Pull off solenoid valves with 3373 see Fig. 3 18. Sealing plug - Take out before removing and installing freewheel - Insert so that tab is located In groove on housing see Fig. 5 - Place O-rings onto sealing plug 19. O-ring - Always replace 20. O-ring - Always replace 21. Operating rod for manual selector valve - Unhooking see Fig. 4 - Install with stepped side facing manual selector valve see Fig. 7 - Adjusting see Fig. 8 Fig. 1 Draining ATF - Place container under transmission. - Remove plug -2-. - Remove overflow pipe -1- and allow ATF to drain. - Screw overflow pipe in onto stop. Fig. 2 Replacing plug seal - Cut open seal -arrow- with side cutting pliers, always replace seal. - After repairs fit new seal to plug and screw in hand-tight when filling with ATF. - Fill with 3 liters of ATF then check ATF level and top-up. Page 5217 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. 4 Speed Automatic 01M Torque Converter: Application and ID 4 Speed Automatic 01M Torque converter, identification There are different types of torque converter. Torque converter with sleeve bearing in turbine shaft of transmission. - New torque converter with integrated needle bearing. Identification is by means of the code letters. The current torque converter may only be installed in the transmission with a sleeve bearing in the turbine shaft. It can be identified by the fourth letter, which is either a B, C, R, T or V. The example (arrow) is a "C". The new torque converter may only be installed in the transmission without a sleeve bearing in the turbine shaft. It can be identified by the fourth letter, which is either a D, H, or J. The example (arrow) is a "D". Note: If a new torque converter with integrated needle bearing is installed in a transmission with a sleeve bearing in the turbine shaft, the sleeve bearing must be removed. Torque converter allocation There are two types, which are allocated according to transmission code letters. Page 2404 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 118 Vehicle Information Sunroof and Central Control Module -J393- Diagnosis Technical Background Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof being interrupted while in operation, or a faulty central control module. Production Solution No production change required. Service Symptoms Sunroof inoperative. Sunroof will not close (stuck open or stuck open in the tilt position). Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position). Warranty When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 6322 - Apply tape to hold edges of leather to steering wheel substrate -arrow-. Leave tape on steering wheel for approx.30 minutes. - Remove tape from steering wheel starting at tape end closest to the outer diameter of the steering wheel and pulling toward center of steering wheel. - Use 3M(R) General Purpose Adhesive Cleaner (Part No.08987) to thoroughly clean leather wrap. - Repeat procedure on additional steering wheel spokes, as necessary. For Golf, GTI, Jetta, New Jetta, New Beetle, New Beetle Convertible, Passat, Passat Wagon and Touareg vehicles: - Install steering wheel.See Repair Manual, Body Interior, Repair Group 69. For Cabrio vehicles: - Install steering wheel.See Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48. Warranty Required Parts and Tools Page 41 If reception does not return: ^ Problem is located further forward in the system. For problems forward of the antenna system: - Continue with Section 3a. For problems at antenna system: Skip to Section 3b. For problems at antenna systems: Tip: All checks should be done outdoors away from buildings. Section 3a - Problems forward of antenna system - First verify connection at Radio (check for bent or crushed connections and proper fit). If all connections appear ok: - Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception). If reception returns: ^ Problem is located between radio and antenna. - Check connections near center console: If connections are OK: - Check resistance of cable from end to end. ^ If More than .4 ohms: - Replace cable. If reception does not return; - Replace radio unit. Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8) If concern is only AM poor / no reception; Locate AM antenna amplifier. ^ Touareg: located above left side window. ^ Passat W8: Sedan above rear window. ^ Passat Wagon: located on left rear window. - Check for proper connections at amplifier both from diversity box and to glass. If connection issue is at glass or on glass: - Glass must be replaced. If connection problem to amplifier: - Repair connection (replace cable or amplifier). Page 4103 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 1242 If the specified value is obtained: - Change to display group 36 as follows: - Press -C- button. - Press buttons -0-, -3- and -6- to input display group number 36 (036) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 36 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by Engine Control Module (ECM). - Check oxygen sensor voltage in display field 1. - Allow engine to run at an increased speed until specified value "B1-P2 OK" appears in display field 4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 1658 Hose/Line HVAC: Description and Operation A/C System Hoses And Lines The mixture of refrigerant oil (PAG oil) and refrigerant R-134a attacks some metals and alloys (for example, copper) and breaks down certain hose material. Use only factory specified replacement hoses and lines. Hoses and lines are fastened together with threaded couplings/fittings and are retained (to bodywork or components) with specially isolated hose clamps. NOTE: - During servicing, all couplings, fittings and related fasteners must be torqued to specifications. - Ensure that only special tools (as specified) are used while servicing. Page 3232 Engine Control Module: Testing and Inspection ECM Voltage Supply Open Circuit, Follow-up Procedure With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply Open Circuit, Correcting All values learned by the Engine Control Module (ECM) and the basic setting values, as well as the readiness code will be erased if the voltage supply is interrupted. Therefore, depending upon the vehicle mileage, it can lead to serious engine running problems. Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test sequence Perform the following operations after voltage supply open circuit: - Switch ignition on for at least 10 seconds. - Switch ignition off. - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. - Check idle speed. Refer to "Fuel Delivery and Air Induction/Idle Speed", See: Fuel Delivery and Air Induction/Idle Speed/Testing and Inspection - Generate readiness code. NOTE: During idling check the Evaporative Emission (EVAP) canister purge regulator valve -N80and the air conditioner are switched off, and the oxygen sensor control learning procedure is initiated. - Perform longer road test until poor driving characteristics are eliminated. Observe the safety precautions when carrying out a road test. During the road test the following operating conditions must be fulfilled: - The coolant temperature must exceed 80 °C When temperature is reached, operating conditions: - Idling - Part throttle - Wide Open Throttle (WOT), and - Overrun must be obtained several times. At Wide Open Throttle (WOT) the speed must exceed 3500 RPM. Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 1578 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long and measure battery voltage. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cu.cm/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.2 volts is measured at battery. Since the voltage at the pump is approx. 2 volts less than battery voltage, there is a minimum delivery rate of 200 cu.cm/30 s. If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply line -1- from fuel filter input. NOTE: Depress buttons on hose connections to do so. - Connect pressure gauge (VAG1318) with adapter (1318/17) to hose. - Repeat test of delivery quantity. If minimum delivery rate is obtained now: - Replace fuel filter. If minimum delivery rate is still not obtained: - Remove Fuel Pump (FP) unit and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 6007 Part 2 Service and Repair Traction Control Switch: Service and Repair Removing and installing is the same for all switches and only the emergency flasher switch -E3- is described here. The switch consists of a switch housing and a switch trim with the relevant symbol. The switch trim is clipped onto the switch housing. If the switch trim is released instead of the switch during the removal sequence, the switch trim must be reclipped onto the switch housing after completing the work. The switch must be pulled, together with the connected wiring, out of the instrument panel to separate the connection. It may be necessary to remove the harness connector of the switch on the left of the relevant switch, so that the wiring to the switch can be pulled out sufficiently. Removing switch - Protect instrument panel around the cover with adhesive tape if necessary. - Release switch carefully from instrument panel using blade of knife or screwdriver and remove. - Release harness connectors and remove. Installing switch - Connect harness connector. - Push switch into mounting and engage. - Clip switch trim onto switch housing if necessary. Page 4782 Part 2 Page 1908 Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove securing bolts - A - from brake caliper. - Remove brake caliper and hang up on body. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove 12-point nut. Central Flap Cable Air Door Cable: Adjustments Central Flap Cable Cables, Installing And Adjusting Central flap cable, installing and adjusting Prerequisites: - Central flap lever correctly adjusted, See Fig. 1 - Heating and ventilation controls are installed. Connecting duct removed. Adjusting - Turn air distribution rotary control knob to left onto stop. - Attach center wire of cable -2- to central flap lever -1-. - Push central flap lever to stop -arrow A- and attach outer cable -2- with clip -3-. Turn air distribution rotary control knob to left and right onto stops. - When turning the rotary control knob both end stops must be reached. Page 5498 Brake Caliper: Service and Repair Rear Brake Caliper Rear brake caliper Notes: ^ When repairing install all parts supplied in repair kit. ^ New brake calipers are filled with brake fluid and pre-bled. ^ Apply a thin coat of assembly lubricant, Part No. G 052 150A2, to brake cylinders, pistons and seals. ^ When repairing, it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installation in the vehicle 1 Self-locking hex bolt, 35 Nm (26 ft. lbs.) ^ Always replace ^ When loosening and tightening counterhold on guide pin 2 Bleeder valve ^ Apply a thin coat of assembly lubricant G 052 1 50 A2 to threads before installing 3 Dust cap 4 Guide pins ^ Grease before pulling on protective cap 5 Protective cap ^ Pull onto brake carrier and guide pin 6 Brake carrier with guide pin and protective cap ^ Replacement part is assembled with sufficient grease on guide pins ^ If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate the guide pins. 7 Protective seal ^ Pull outer sealing lip onto piston Specifications Crankshaft Gear/Sprocket: Specifications Camshaft sprockets Mounting bolts 100 Nm Vibration damper Mounting bolt 100 nm + 1/4 turn Page 650 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 5525 ^ Insert brake pads and brake pad retaining springs (arrows) into brake carrier. ^ Install brake caliper housing with new self-locking bolts and torque to 35 Nm (26 ft. lbs.). Note: The repair kit includes four self-locking bolts, which must always be installed. ^ Press brake lever -2- in direction of arrow and attach parking brake cable. ^ Install clip -1-. ^ Adjust parking brake. ^ Operate foot brake first after adjusting parking brake. ^ Install wheels. Notes: ^ After each brake pad change firmly depress the brake pedal several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. ^ After changing brake pads check brake fluid level. Page 3247 Engine Control Module: Tools and Equipment Wire Terminal Extractor AST tool# H 4673-9 Page 1945 - Disconnect 5-pin connector from ignition coil (N152). - Disconnect fuse no. 32 from fuse block. Note: By removing fuse 32, the voltage feed to the injector valves is interrupted. - Completely depress accelerator pedal for wide open throttle. - Check compression pressure with compression pressure tester VAG 1763. - Crank engine until tester no longer shows an increase in pressure. Compression pressure readings: New: 10 - 13 bar Max. wear: 7.5 bar Permissible variation between all cylinders: 3 bar Page 6140 Fuse Block: Application and ID Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A Page 4379 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 6097 Part 2 Page 5867 Special tools, testers and auxiliary items - Commercially available hydrometer - Shop rags NOTE: - Minimum battery temperature of 10 °C (50 °F) is required when carrying out specific gravity tests. - Specific gravity of all cells must be checked. - Switch ignition off - Remove all battery cell caps. Page 5602 - Install VAG 1310/26 at each port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". NOTE: Once the brake pressure leak test has been completed, the hydraulic brake system MUST be purged of any entrained air. See Repair Manual Group 47, Brake System Bleeding. Warranty Information only. Required Parts and Tools No Special Parts required. Always see ETKA for the latest part(s) information. Page 5625 - Install VAG 1310/26 at each port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". NOTE: Once the brake pressure leak test has been completed, the hydraulic brake system MUST be purged of any entrained air. See Repair Manual Group 47, Brake System Bleeding. Warranty Information only. Required Parts and Tools No Special Parts required. Always see ETKA for the latest part(s) information. Page 5364 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 6307 - Remove bolts -1- and -2-. - Support sub-frame with engine/transmission jack VAG 1 383A. - Remove bolts -1-. - Remove bolts -2- and -3-. - Lower sub-frame with engine/transmission jack VAG 1 383A. - Remove return line clamp -1- and unscrew line fitting at steering gear -2-. - Remove power steering gear bolts. - Take power steering gear out to rear. Installing NOTE: ^ Use new O-rings for hose line connections. ^ Coat O-rings with lubricant before installing steering gear. ^ After connecting steering gear to universal joint shaft ensure seal lies against assembly plate without kinking and opening to footwell is correctly sealed. Otherwise noises or water leaks may be develop later. Page 4565 Test Step 1 Page 2990 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long and measure battery voltage. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cu.cm/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.2 volts is measured at battery. Since the voltage at the pump is approx. 2 volts less than battery voltage, there is a minimum delivery rate of 200 cu.cm/30 s. If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply line -1- from fuel filter input. NOTE: Depress buttons on hose connections to do so. - Connect pressure gauge (VAG1318) with adapter (1318/17) to hose. - Repeat test of delivery quantity. If minimum delivery rate is obtained now: - Replace fuel filter. If minimum delivery rate is still not obtained: - Remove Fuel Pump (FP) unit and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): Brake Pads (Rear) - Apparent Premature Wear Brake Pad: Customer Interest Brake Pads (Rear) - Apparent Premature Wear Group: 46 Number: 02-01 Date: Apr. 15, 2002 Subject: Rear Brake Pads, Appear to be Worn Prematurely Model(s): Golf, Jetta, New Beetle 2000, 2001 Cabrio 2001 Supersedes T.B. Group 46 Number 00-01 dated Nov. 27, 2000 Condition While inspecting front and rear brake pads, the rear brake pads appear to be prematurely worn. May be caused by aggressive brake pedal application and a softer brake pad composition. Service When inspecting a customer's brake system: If rear brake pads appear to be prematurely worn: - Inspect front brake pads. If front pads are original (factory) pads and are still good. - Install new rear brake pads Part No: 1J0 698 on vehicle, See appropriate Repair Manual CD-ROM, Group 46 - Rear Wheel Brakes Disc brakes, serving". CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. When procedure applies to vehicles within the first 12 months or 12,000 miles/20,000 km, (whichever occurs first) of the Limited New Vehicle Warranty period, use the table shown. Note: For vehicles which have exceeded 12 months or 12,000 miles/20,000 km (whichever occurs first) of the Limited New Vehicle Warranty period, contact your FOM. Page 2834 Oxygen Sensor: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Specifications Spark Plug: Specifications Spark Plugs AFP VW Part Number ................................................................................................................................. ................................................. 101 000 035 AH Manufacturer Designation (NGK) ............................................................................................................................................................ BKR 5 EKUP Spark Plug Gap ............................................................................................................. ....................................................................................... 0.7 mm Tightening Torque .......................... ...................................................................................................................................................... 25Nm (18 ft. lb.) Page 3140 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 6021 Fuse Block: Fuse and Fusible Link Locations Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A Page 5183 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: Customer Interest Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 2165 16 - Change - Over Barrel. Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 3213 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 819 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Page 2624 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3836 NOTE: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator: - Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. - Switch ignition off. - Now check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow -arrow-). - Observe pressure drop on pressure gauge. If pressure does not drop: - Test check-valve of Fuel Pump (FP), Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking If pressure does drop again: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator: Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. If pressure does drop again: - Check whether line connections, O-rings in fuel rail, and fuel injectors are properly sealed. - Check whether pressure gauge is properly sealed. NOTE: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. Page 5968 Starter Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 1725 - The engine/transmission angle has changed and therefore the lower edge of the oil fill hole -1- is located below the new oil level -2-. - To properly check oil level, transmission must be drained completely and re-filled. Tip: The transmission housing must be cleaned and dried before servicing. Shift fork pins must be removed in order to drain transmission. Selector shaft, securing ^ Remove air cleaner housing. ^ Remove sound insulation. ^ Clean and dry transmission. ^ Secure selector shaft so that the position of shift fork pins can not move: ^ Press selector shaft down arrow -1^ While selector shaft is held in down position, turn bracket -A- upward (clockwise) in direction of arrow -2- and press inward until the bracket latches in selector shaft. Tip: Use a clean 3.0L container with graduated markings to catch draining oil Transmission, draining Page 1864 The display shows: - Move the position indicator -arrow- on the display to the left, until 0 is shown above the scroll bar -1-. - On the display, press Save Button -2-. The display shows: - On the display, press "Accept" -arrow-. Page 158 Power Door Lock Control Module: Electrical Diagrams For information regarding diagrams for the Door Control Module, please refer to the Body Control Systems / Diagrams. Driver side with Seat Memory Passenger side with Seat Memory Also found in Comfort System / Diagrams. Driver side with Power Windows Passenger side with Power Windows Page 5953 Starter Motor: Application and ID Starter The following starters are installed: > 04.00 production - 4-cylinder gasoline engines: 12 V - 1.1 kW - 2.8L gasoline engine: 12 V - 2.0 kW - 4-cylinder TDI engine: 12 V - 2.0 kW 04.00 > production Modified starters are installed in vehicles with 4- cylinder TDI engines (note replacement part number). - Vehicles with manual transmission: 12 V - 2.0 kW - Vehicles with automatic transmission: 12 V - 2.4 kW Page 4122 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3369 - Additionally, check wires all for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Heater Check Heated Oxygen Sensor (HO2S) -G39- Before Three Way Catalytic Converter (TWC), Checking NOTE: Only gold plated terminals may be used to repair the contacts in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display Read Measuring Value Block Input display group number XXX Page 2848 - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor behind catalytic converter must be OK. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor After TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals If specified values are obtained: - End diagnosis and switch ignition off. If specified values are not obtained: - End diagnosis and let engine continue to run at idle. - Check primary voltage. Checking primary voltage - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 5235 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 3226 Engine Control Module: Locations J220 - Motronic Engine Control Module (ECM) J220 - Motronic Engine Control Module (ECM) - in plenum, center - for gasoline engine with motronic MFI Page 3731 - Carry out road test with 2nd person to observe display. Observe safety precautions when carrying out road test. Refer under "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions - Observe figure displayed in display field 3: Specified value: approx. driven speed Display Group 005 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If no speed is displayed: - Remove wiper arms and plenum chamber cover. M/T - Humming Noise When Turning at Low Speeds Fluid - M/T: All Technical Service Bulletins M/T - Humming Noise When Turning at Low Speeds 34 06 02 June 12, 2006 2011899 Affected Vehicles Supersedes TB Group 34 number 06-01 dated June 5, 2006 due to Golf model Condition Customer States Humming Sound From Front of Vehicle During Cornering Customer may state humming sound coming from front of vehicle on turns in vehicles equipped with 02J or 0A4 manual 5 speed transmission. The hum may be more noticeable during slow speed turning maneuvers with steering wheel almost to full travel. The hum diminishes with steering wheel straight. Technical Background Hum may be generated by the differential spider gear contacting the one piece thrust washer when under load. Production Solution New transmission oil Part No. G 055 726 A2 incorporated in transmission production plant. Transmissions with new oil installed begin with VINs in table. Service 0A4 Manual 5 Speed Transmission, Draining and Re-filling If the vehicle exhibits this condition, drain and re-fill transmission as follows: - It is no longer possible to accurately check transmission oil level in the same manner as previous model years. Page 3700 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3598 Display Group 030 Explanation of 3 digit number block in display field 2 Page 2020 Piston: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 1261 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- from Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). - Check wiring for open circuit between test box and 6-pin harness connector (to control module) according to wiring diagram. Terminal -1- + socket 70 - Terminal -2- + socket 71 - Terminal -5- + socket 51 - Terminal -6- + socket 52 - Wire resistance: Max. 1.5 ohms Page 4864 Separate master cylinder operating rod from clutch pedal as follows: - Insert release tool 3309 in clutch pedal cutouts (arrow A). Inscription "top/open" (B) points away from clutch pedal. - With pliers 10-208A positioned in recesses (arrow C), press release tool together. - Turn stop -A- for clutch pedal in direction of arrow and remove. - Push slave cylinder in direction of arrow -1- onto stop. Slave cylinder must not be covered in upper area by over-center spring mounting (arrow 2). - Swing slave cylinder in direction of arrow 3 out of mounting bracket. Installing Installation is carried out in the reverse sequence, when doing this note the following: Page 4576 Test Step 1 - 2 M/T - Humming Noise When Turning at Low Speeds Fluid - M/T: Customer Interest M/T - Humming Noise When Turning at Low Speeds 34 06 02 June 12, 2006 2011899 Affected Vehicles Supersedes TB Group 34 number 06-01 dated June 5, 2006 due to Golf model Condition Customer States Humming Sound From Front of Vehicle During Cornering Customer may state humming sound coming from front of vehicle on turns in vehicles equipped with 02J or 0A4 manual 5 speed transmission. The hum may be more noticeable during slow speed turning maneuvers with steering wheel almost to full travel. The hum diminishes with steering wheel straight. Technical Background Hum may be generated by the differential spider gear contacting the one piece thrust washer when under load. Production Solution New transmission oil Part No. G 055 726 A2 incorporated in transmission production plant. Transmissions with new oil installed begin with VINs in table. Service 0A4 Manual 5 Speed Transmission, Draining and Re-filling If the vehicle exhibits this condition, drain and re-fill transmission as follows: - It is no longer possible to accurately check transmission oil level in the same manner as previous model years. Page 637 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant Page 4948 Wheel Bearing: Aftermarket Tools Rear Wheel Bearing Press AST tool# 3420 VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle. - VW/Audi Rear Wheel Bearing Press - Applicable to Newer Golf, Jetta and New Beetle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Engine Controls - DTC's 00545/00638 Stored PROM - Programmable Read Only Memory: Customer Interest Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 3854 8 - 6 Nm (53 in. lb) 9 - Filter element 10 - Air cleaner lower section 11 - Air duct 12 - 10 Nm (ft lb) 13 - O-ring Always replace if damaged 14 - Intake hose Ensure seated tightly - Press together at front to release - To Secondary Air Injection (AIR) pump motor -V101-: 15 - Connecting hose For crankcase breather - From breather housing on cylinder head cover 16 - Connecting hose Note installation position - From T-piece connection on intake manifold upper section /Evaporative Emissions (EVAP) canister purge regulator valve -N8017 - Positive Crankcase Ventilation (PVC) heating element -N79- For crankcase breather 18 - To throttle valve control module -J338-* Page 5719 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 1909 - Pull off wheel bearing/wheel hub unit from stub axle. - A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Caution: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 ab. - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake disc. Specifications Pressure Plate: Specifications Pressure plate bolts Two-part flywheel 13 Nm Tighten evenly in diagonal sequence single peice flywheel 20 Nm Page 6125 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Locations Manifold Pressure/Vacuum Sensor: Locations G71 - Manifold Absolute Pressure (MAP) sensor Page 4361 1. Circlip - Mark after removing and insert in same position 2. Thrust plate - Smooth side facing inner plates 3. Inner plate 4. Outer plate 5. Corrugated washer 6. Circlip - Removing and installing see Fig. 1 - Installation position see Fig. 2 7. Spring supporting plate - With springs - Installation position see Fig. 2 8. Spring supporting ring 9. Piston - Sealing lips are vulcanized to piston - Moisten sealing lips with ATF before installing - Turn piston slightly when installing 10. Clutch housing Page 2384 Coolant Reservoir: Locations Underhood View: Always heed all WARNINGS: See: Maintenance/Service Precautions Always exercise extreme caution when working under the engine hood. Gasoline Engine 174 Hp (2.8L) 1 - Windshield washer container 2 - Coolant expansion tank 3 - Engine oil dipstick 4 - Engine oil filler cap 5 - Brake fluid reservoir 6 - Vehicle battery (protected by a cover} Page 4291 ^ Updated software level "0003", "0004", "0005", "0007" or "0009" (depending on ECM Part No.) will appear at (arrow). ^ Flash CD can now be removed from VAS 5051 or VAS 5052 Diagnostic tool. - Print the ECM screen to verify ECM update software level. ^ VAS 5051 will print to printer immediately. ^ VAS 5052 will hold the print until process is complete and then you may take the tester to the printer for printing the screen. - Attach print to vehicle Repair Order. - Select "Go to" then select "Exit". Note: It is not generally necessary to encode the ECM following the "update - Programming" (flashing procedure. However, you must set the readiness code. - Set readiness code. ^ Use VAS 5051 or VAS 5052 to set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, see the table. Diagram Information and Instructions Blower Motor Switch: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1198 - Measure sensor resistance between terminals 2 + 3 at connector to sensor. Specified value: 480...1000 Ohm - Check sensor for shorts between terminals 1 + 2 and 1 + 3. Specified value: infinite Ohm If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28-: Vehicles with engine code AFP, item 25, - Vehicles with engine code BDF, item 16. - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 108 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no DTC is found on sensor: - Connect test box to control module wiring harness connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Terminal 2 + socket 90 Terminal 3 + socket 82 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Remove sensor and check sensor wheel for secure fit, damage, and run-out. NOTE: There is a larger-sized gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If nothing seems to be wrong with the sensor wheel: - Replace Motronic Engine Control Module (ECM) -J220-. Page 435 Interior Lighting Module: Electrical Diagrams For information regarding diagrams for the Interior Lights, please refer to the Body and Frame / Comfort System Diagrams. With Power Windows Page 64 - Antenna cables - double DIN (Premium VI) radio. - Antenna cables - Phaeton 2004 > 2006 - Antenna cables - Satellite radio (Hard top vehicles) Page 188 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 5900 Alternator Pulley: Aftermarket Tools Multi-toothed Alternator Pulley Wrench AST tool# H 2592 Used for the R and R of the free-wheel pulley on the alternator. This tool is comparable to VW factory tool# 3400 and Mercedes factory tool # 602 589 00 10 00. The H 2592 is used in conjunction with the S 3054 X-10 or the S 1054TX T-50 sockets. Applicable to the following Mercedes Engines: 602.982, 611.981, 611.987, 612.965, 612.966, 612.981, 613.960, 628.962, 628.963, 642.992, 646.951, 646.961, 646.962, 646.963, 647.961 and 647.981 - Applicable to VW - Comparable to VW Factory Tool # 3400 - Comparable to Mercedes Factory Tool # 602 589 00 10 00 Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: Page 4498 Fluid - A/T: Service and Repair 5 Speed 09A Transmission ATF, Replacing - Remove sound insulation tray. - Place drip tray under transmission. - Remove drain plug (arrow) in transmission housing. - Drain ATF. - Screw in drain plug with new seal and tighten to 45 Nm. If ATF needs to be topped up, then only ATF with Part No. G 052 990 A2 may be used. - Fill with approx. 2.5 liters of ATF (G 052 990 A2) through filler pipe. - Start engine and shift through all selector lever positions with vehicle stationary. - Check and top up ATF level. Page 119 Central Control Module: Locations Comfort System and Central Locking System, Assembly Overview 1 - Coupling station Installation position: Lower A-pillar, covered by trim in footwell - Remove A-pillar lower trim to remove 2 - Door control module, FR For comfort system only - Integrated into window motor - Removing: Remove door trim - Remove window motor. 3 - Door lock, FR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 4 - Coupling station Installation position: B-pillar Page 2240 - Install bearing bolt with collar for sliding rail and tighten to 10 Nm. Note: If the cylinder head is removed: - Install cylinder head - Push sliding rail onto bearing bolt. Insert short mounting screw with "D6" locking compound and tighten both bolts to 20 Nm. - Place camshaft roller chain on intermediate shaft (note direction of travel). - Mount camshaft sprocket and roller chain on camshaft for cylinder bank 1, 3 and 5 (long camshaft) and counter tighten by hand. - Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and tighten by hand. Note: Coat contact surfaces of the bolt heads with oil when installing. - Remove camshaft guide 3268. - Tighten mounting bolts for camshaft sprockets to 100 Nm. Note: Hold camshaft -arrow- only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02 and install. Tighten mounting bolt to 10 Nm. - Replace oil seal for sealing flange. - Prepare cylinder head gasket for assembly. - Coat sealing surface of cover piece with AMV 188 001 02. - Coat O-ring for oil passage seal and insert in cover piece. - Install cover piece, insert all mounting bolts and turn in opposite direction slightly. - Initially tighten 8 mm mounting bolts to 25 Nm, then tighten 6 mm mounting bolts to 10 Nm. - Install chain tensioner for camshaft roller chain and tighten to 40 Nm. Capacity Specifications Refrigerant: Capacity Specifications A/C Refrigerant Capacity (R134a) Compressor Manufacturer Quantity SDV7-V16 Sanden 750 ± 50g (26 ± 1.8 oz) DCW-17D Zexel 750 ± 50g (26 ± 1.8 oz) Page 1666 Brake Fluid: Service and Repair Checking brake fluid level: The brake fluid reservoir is below the left side of the plenum panel. See illustration. The correct fluid level is important for the proper functioning of the brake system. The fluid level in the brake fluid reservoir should always be between the "MAX" and "MIN" markings. The fluid level may drop slightly after some time due to the automatic adjustment of the brake pads. This is no cause for alarm. STOP! If the brake fluid level falls considerably below the "MIN" mark, the brake warning light will come on. Do not continue to operate the vehicle. The complete brake system should be thoroughly checked by a VOLKSWAGEN dealer or another qualified workshop and the cause corrected. The brake warning lamp lights up to indicate a low fluid level in the reservoir. Contact a VOLKSWAGEN dealer immediately. Changing brake fluid: The brake fluid reservoir can be difficult to reach, therefore, we recommend that you have the brake fluid changed by your authorized VOLKSWAGEN dealer. Your dealer has the correct tools and know-how to do this for you. Brake fluid absorbs moisture from the air. If the water content in the brake fluid is too high, corrosion in the brake system may result after a period of time. The boiling point of the brake fluid will also decrease considerably. Therefore, the brake fluid must be changed every 2 years. Note Remember that brake fluid is harmful to the paint of your vehicle. Because of the problem of proper disposal of brake fluid along with the special tools required and the necessary expertise, we recommend that you have your brake fluid changed by your VOLKSWAGEN dealer. It is advisable to have the fluid changed during a Maintenance Service. WARNING Brake failure can result from old or inappropriate brake fluid. Observe these precautions: ^ Use only brake fluid that meets SAE specification J1703 and conforms to Federal Motor Vehicle Standard 116. Always check with your authorized Volkswagen dealer to make sure you are using the correct brake fluid. The correct type of brake fluid is also found labeled on the brake fluid reservoir. ^ The brake fluid must be new. ^ Brake fluid is poisonous. Therefore, it must be stored only in the closed original container out of reach of children. Page 3237 - The respective fuses of Motronic Engine Control Module (ECM) - J220- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Generator (GEN) must be OK, checking. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. Test sequence - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Checking voltage supply terminal 30 - Measure voltage supply between sockets 1 + 62 and 2 + 62 of test box. Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram: - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking voltage supply terminal 15 - Measure voltage supply between sockets 1 + 3 and 2 + 3 of test box. - Switch ignition on. - Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2944 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 3363 If the specified value is obtained: - Change to display group 32 as follows: - Press -C- button. - Press buttons -0-, -3- and -2- to input display group number 32 (032) and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 32 -> 12 - Check oxygen sensor control learned value at idling (additive) in display field 1. - Check oxygen sensor control value at part load (multiplicative) in display field 2. Page 4297 - Test-drive vehicle and inspect transmission for signs of leakage. Page 2040 - Disconnect flow hose -1- (with white marking) and return hose -2- (with blue marking) and catch leaking fuel with a clean rag. Note: In order to do this, press the tabs at the hose couplings together. WARNING: The fuel system is pressurized. Before opening the system, plane a clean rag around the connection. Then reduce pressure by carefully and slowly loosening the connection. - Plug lines so that dirt cannot enter fuel system. - Remove middle, left and right damping pans. - Put lock carrier into service position, please refer to: Vehicle /Body and Frame /Radiator support/ Service and repair. See: Body and Frame/Lock Carrier/Service and Repair/Procedures Vehicles with air conditioning - Remove V-ribbed drive belt. - Remove A/C compressor. - Unscrew refrigerant line retainer clamp(s). WARNING: Do not open the A/C system refrigerant circuit. Notes: Opening the refrigerant circuit can be done only in shops which have available properly trained personnel as well as all of the necessary tools and equipment. - To avoid damage to the condenser, coolant lines and hoses, make sure that the lines and hoses are not being overstretched, crimped or bent. Continued for all vehicles - Remove combination valve. - Unscrew upper intake manifold from lower intake manifold. - Remove upper intake manifold and place it on a suitable surface so that vacuum actuator will not be damaged. Note: Plug the intake ducts in the lower intake manifold or cylinder head with a clean rag. - Remove cylinder head cover. Installing The installation takes place in the reverse order. Notes: If damaged or leaking, replace cylinder head cover. - First, screw the upper intake manifold to the lower intake manifold, then tighten both manifold support screws. - Make sure the fuel hoses are firmly connected. If necessary, refill coolant. - Check DTC memory. - Adjust basic settings. - Check readiness code. - If error memory was erased or engine control unit was disconnected from positive continuous voltage feed, regenerate readiness code. Tightening torque Cylinder head cover to cylinder head 10 Nm Upper intake manifold to lower intake manifold 25 Nm Upper intake manifold to support right and left 25 Nm Page 2895 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams With Manufacturer's Scan Tool Catalytic Converter: Testing and Inspection With Manufacturer's Scan Tool Catalytic converter, checking Special tools, equipment, test and inspection devices; required accessories - V.A.G 1551 scan tool Note: The VAG 1552 system tester may also be used in place of the V.A. G 1551 scan tool, except that no printout can then be made. - V.A.G 1551/3 cable Test sequence - Connect VAG 1551 (or VAG 1552) scan tool. Leave engine running and select engine control unit using "address word" 01. Diagnosing the aging of oxygen sensors (sensor dynamics) Indicated on display Press keys "0" and "4" for function "start basic setting" and acknowledge entry with "Q". Indicated on display Press "0", "3" and "4" for display group 34 and acknowledge with "Q". Page 5932 ^ Verify remote has not lost synchronization. Tip: DTC 00956, No or Incorrect Basic Settings/Adaptation is a direct result of lost synchronization. Additionally, loss of only 1 remote's functionality can be a result of DTC 00956. NOTE: Synchronization is not a warrantable concern. Synchronization Procedure Model(s) Procedure (A5) Jetta, GTI/Rabbit/R32, Eos, - Switch ON ignition with spare key. Tiguan, Jetta Sport Wagen - Unlock driver door manually by inserting main key in driver door lock cylinder. - Press unlock button once on remote. - Remove spare key from ignition lock cylinder. - Close driver door and verify remote functionality. (B6) Passat Sedan, Wagon, & CC Tip: Care must be taken when removing cover from door handle to expose lock cylinder. - Unlock driver door manually with emergency key (spare). - Switch ON ignition with main key. Touareg & Phaeton - Unlock driver side door manually using door lock cylinder. - Switch ON ignition. (B5) Passat, Passat Wagon - Press lock or unlock button (ONE TIME) for one second. (A4)Golf/Jetta (including Wagon) - Vehicle remains locked. Euro Van - Control unit recognizes only one key code via the master key. City Golf/Jetta - Lock or unlock vehicle with MASTER KEY. New Beetle/New Beetle Convertible - Procedure is complete. If remote is still inoperative, perform the following: ^ Remove battery from remote; see Repair Manual Group 57 - Front doors, Central locking system, Central locking system, in ElsaWeb. ^ Perform a capacitive discharge by pressing down for 5 seconds any button on remote with battery removed. ^ Install new battery and reassemble remote in reverse order. Tip: Observe polarity of battery when installing. The positive terminal is marked in the remote housing and on battery. Verify operation of remote. If remote remains Inoperative, perform ALL of the following: ^ Remove new battery and verify surface voltage is at least 3.0 V ^ Perform an additional capacitive discharge by pressing down any button on remote for 5 seconds while battery is removed. This will erase the battery memory of the remote. ^ Reinstall new battery. Reassemble remote in reverse order. Verify red LED is illuminating when a button is pressed. Recall 07V063000: Brake Light Switch Replacement Brake Light Switch: All Technical Service Bulletins Recall 07V063000: Brake Light Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 1999-2006 Volkswagen/GTI 1999-2006 Volkswagen/Jetta 2001-2005 Volkswagen/New Beetle 2001-2007 Volkswagen/R32 2004 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 07V063000 MFG'S REPORT DATE: February 15, 2007 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 790000 SUMMARY: On certain passenger, wagon, and convertible vehicles equipped with or without cruise control, a brake light switch may malfunction if it was installed incorrectly. CONSEQUENCE: The brake lights could become inoperative, or remain on. Failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before April 27, 2007. Vehicles within the make, model, and model year of this population may be involved in either this recall or 06V-183, but not both. The remedy is the same for each recall. Volkswagen dealers will apply the remedy based on the VIN number of the vehicle. Owners may contact VW at 1-800-822-8987. NOTES: Volkswagen recall No. N4. Customers may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Page 1181 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 1784 Refrigerant: Description and Operation The following designations are used and appear on component labels and factor tags: - R-134a - Tetrafluoroethane - CH2F CF3 - H-KW 134a - SUVA(R) 134a - ARCTON(R) 134a Color Refrigerant R-134a is colorless and is invisible as a gas. R-134a when viewed through the sight glass may appear milky due to the mixture of refrigerant and lubricating oil (PAG oil). Temperature/pressure relationship R-134a in an enclosed container will have a specific temperature/pressure relationship. Temperature in °C (°F) Pressure in bar (psi) -30 (-22) 0.0 (0.0) -20 (-4) 0.3 (4.4) -10 (14) 1.0 (14.5) 0 (32) 1.9 (27.5) 10 (50) 3.1 (45.0) 20 (68) 4.7 (68.2) 30 (86) 6.7 (97.2) 40 (104) 9.1 (132.0) 50 (122) 12.2 (177.0) 60 (140) 15.8 (229.2) 70 (158) 20.2 (293.0) Refrigerant oil A special Polyalkylene Glycol (PAG) synthetic oil is used in R-134a systems. This oil is NOT compatible with mineral based oils used in R-12 systems. See: Heating and Air Conditioning/Service Precautions Airborne properties Escaped refrigerant gases are heavier than air and will gather first in low places, like under the car. R-134a refrigerant gas displaces oxygen and may cause suffocation in low areas of poor air circulation. Refrigerant R-134a is not poisonous in any state (liquid or gas) and is safe when used properly. Affects on plastic Refrigerant R-134a will deteriorate some plastics. Therefore, when making system repairs, use only genuine WV replacement parts which are specified for use with R-134a refrigerant. Affects on metal In its pure state, refrigerant R-134a is chemically stable and will not attack iron, copper, brass or aluminum. However, the mixture of R-134a and PAG oil may deteriorate certain metals (copper). Therefore, when making system repairs, use only genuine WV replacement parts which are specified for use with R-134a refrigerant. Water solubility Liquid R-134a refrigerant will absorb only very minute quantities of moisture. However, R-134a vapor can absorb large amounts of moisture. Flammability R-134a refrigerant is not flammable. Refrigerant containers Page 38 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -4-. ^ Location: Above rear glass under headliner. Antennas All models use four antennas. ^ Antennas -2-, -7- and -8- (for FM reception). Integrated into rear glass -5^ Antenna -3- (for AM and FM reception). Integrated into rear glass -5-. - Jetta / Golf / Passat (non W8) - Antenna system ^ All models use External amplified antenna mast -1-. Page 2213 Marking roller chains - Mark roller chains before removal (e.g., put an arrow in direction of travel with paint). Note: Do not mark the chain with a center punch, chisel, etc. - Remove bolts - arrows - from the timing chain upper guard rail. Page 2431 - Use auxiliary cables from VAG 1594 A to bypass contact -1- and contact -2- of attachment plug. Stage 1 of coolant fans (V7) and (V35) should start. - Switch ignition on. - Use auxiliary cables from VAG 1594 A to bypass contact -2- and contact -3- of attachment plug. Stage 2 of coolant fans (V7) and (V35) should start. If Stage 1 or 2 of the fans does not start: Use wiring diagram to find and repair open circuit. If no open could be found: Replace fan -V7- or fan -V35-, respectively. Page 1308 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 6405 - Position a wooden block approx. 100 mm (3.34 inch) long between rear axle and body. - Position VW 771 slide hammer and pull out bonded rubber bushing Installing Bonded rubber bushing has mark -1- on face. - Mark must align with edge (arrow) on trailing arm -2-. - Mark position of mark -1- on bonded rubber bushing. - Assemble special tool with bonded rubber bushing. - Install bonded rubber bushing and special tool on rear axle. Ensure mark aligns with trailing arm edge. - Install (pull in) bonded rubber bushing by turning spindle. - Check position of bonded rubber bushing after installing. Continue rear axle installation in reverse sequence Page 3931 - Disconnect vacuum line from fuel pressure regulator (arrow). The fuel pressure must increase to approx. 3.0 bar. - Switch ignition off. If the specified value is not obtained: - Check quantity supplied by fuel pump. If the specified value is obtained: - Check for leaks and holding pressure by observing pressure drop on gauge. After 10 minutes there must be a residual pressure of at least 2.0 bar. If the holding pressure drops below 2 bar: - Start engine and run at idle. - Switch ignition off after pressure has built-up. At the same time close pressure gauge cut-off valve (handle perpendicular to direction of flow (arrow)). - Observe pressure drop on gauge. If the pressure does not drop: - Check fuel pump non-return valve. If the pressure drops again: Page 1189 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test With Manufacturer's Scan Tool Brake Signal: Testing and Inspection With Manufacturer's Scan Tool Brake Light Switch and Brake Pedal Switch Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuses 5, 10, 13 and 29 OK - Battery voltage at least 11.5 V Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block HELP Input display group number XXX - Press buttons -0-, -6- and -6- to input display group number 66 (066) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 66 -> 1234 - Observe display in display field 2 (3rd and 4th positions from left): Specified value: x x 0 0 - Depress brake pedal and observe display in display field 2. Specified value: x x 11 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. If the display does not change: - Disconnect 4-pin harness connector from brake light switch and brake pedal switch. - Measure resistance between terminals -1- + -4- of switch. Specified value with brake pedal not depressed: Infinity ohms Specified value with brake pedal depressed: max. 1.5 ohms Page 5346 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 1314 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (6 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (6 spd. Manual transmission) Locations Low Pressure Sensor / Switch: Locations F129 A/C Pressure Switch - engine compartment, right rear Page 3318 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 5404 ^ Turn ignition switch to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics" ^ Select "07 - Code control unit" <-- Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J ^ Press the "Q" button to confirm Note: On the display, in the upper right corner, the control module part number and coding are displayed ^ Press <-- button ^ Select "06 - End output" ^ Disconnect VAS 5051 from vehicle ^ Recode radio and reset radio preset stations ^ Reset clock ^ Where applicable, reset power window pinch protection ^ Turn ignition to "OFF" position ^ Proceed to Section E Section E Section E - Brake Bleeding ^ Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING! Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 Note: Page 1901 Special tools, testers and auxiliary items required ^ Thrust pad 40 - 105 ^ Press tool 3283 ^ Collar for wheel bearing inner race 3423 ^ Engine and transmission jack V A.G 1333 A with universal transmission mount V.A.G. 1359/2 ^ - 2 - Puller Kukko 18/0 Special tools, testers and auxiliary items required ^ Foot pump with high pressure hose V.A.G. 1389A/1 If there is a hand pump V.A.G. 1389/1 available in the dealership it can be converted to a foot pump. To do this use the conversion kit V.A.G. 1389/4. Page 1850 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 45 - Antenna cables - Touareg 2004 > 2006 Tip: Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information. Page 3655 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 2405 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 209 Seat Heater Control Module: Electrical Diagrams For information regarding diagrams for the Seat Heater Control Module, please refer to Seat Heater Diagrams. With leather seats Driver's side See: Body and Frame/Seats/Seat Heater/Diagrams/Electrical Diagrams/Heated Seats - Leather, From May 1999 Passenger's side See: Body and Frame/Seats/Seat Heater/Diagrams/Electrical Diagrams/Heated Seats - Leather, From May 1999 Without leater seats Driver's side See: Body and Frame/Seats/Seat Heater/Diagrams/Electrical Diagrams/Heated Seats, From May 1999 Passenger's side See: Body and Frame/Seats/Seat Heater/Diagrams/Electrical Diagrams/Heated Seats, From May 1999 Page 4344 Page 6132 Relay Arrangements On The Relay Panel Page 1457 Part 2 Page 4355 Fig. 1 Installing rollers and springs - Insert springs so that spring (arrow) engages in cage. Fig. 2 Inserting cage with springs and rollers - Install with large tabs (arrow) facing up. Fig. 3 Securing cage - Secure cage by turning in direction of arrow as far as stop. Fig. 4 Installed position of piston - Insert piston -A- as shown. Page 1500 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 2426 Part 2 Page 1182 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). CAN-Bus, Checking Engine Control Module: Testing and Inspection CAN-Bus, Checking With Manufacturer's Scan Tool Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. Page 1824 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Outside Air Temperature Sensor -G17- (Where Applicable) Ambient Temperature Sensor / Switch HVAC: Locations Outside Air Temperature Sensor -G17(Where Applicable) Outside Air Temperature Sensor -G17- (where Applicable) Sensor -arrow- located on left of front bumper behind outer air grill. Unclip air grill to remove sender. Page 5421 Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing Note: Tire and wheel removal is not necessary Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening Note: The label showing supplier code is upside down in vehicle ^ If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C ^ If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation ^ Obtain radio code and record radio preset stations ^ Turn Ignition Switch to "OFF" position ^ Open hood and place fender cover in position ^ Disconnect the ground cable (GDN) from the negative (-) battery terminal <-- Disconnect electrical connector -1- from mass air flow sensor -2<-- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) Page 320 Electronic Brake Control Module: Locations ABS Control Module With Electronic Differential Lock, (EDL) and Anti-Slip Control (ASC) (From August 2000) ABS control module with electronic differential lock, (EDL) and anti-slip control (ASC) (from August 2000) Page 1986 Connecting Rod Bearing: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprockets Mounting bolts 100 Nm Vibration damper Mounting bolt 100 nm + 1/4 turn Page 5521 ^ Press piston back. ^ Insert inner brake pad. When the brake pad is installed, the arrow on the brake pad backing plate -A- must point downward. Ensure that the brake pad is installed correctly! ^ Install outer brake pad to brake carrier. ^ Pull protective foil off outer brake pad backing plate. ^ Install brake caliper housing with both guide pins (arrows) to brake carrier. ^ Install both protective caps. ^ Insert retaining spring into brake caliper housing. Page 1631 Ribbed Belt: Testing and Inspection Ribbed Belt, Checking NOTE: Always replace ribbed belt if found to be faulty. This will avoid related break-downs or operating problems. - Lift vehicle and check condition of ribbed belt -1-. - Crank engine by hand at vibration dampener/pulley -arrow-. Check ribbed ribbed belt for: - Sub-surface cracks (cracks, core ruptures, cross sectional breaks) - Layer separation (top layer, cord strands) - Base break-up - Fraying of cord strands - Flank wear (material wear, frayed flanks, flank brittleness -glassy flanks- surface cracks) - Traces of oil and grease Page 2345 Coolant: Fluid Type Specifications Coolant (Antifreeze), Mixing Precautions Models: All New antifreeze, Part No: G 012 A8F A4: Color = Purple Replaces Part No: ZVW 237 G12 (Pink) Can be mixed with ZVW 237 G12 (Pink) DO NOT mix with ZVW 237 105 (green) or any aftermarket antifreeze DOES NOT replace Part No: ZVW 237 105 (green) Antifreeze, Part No: ZVW 237 G12: Color = Pink Can be mixed with G 012 A8F A4 (purple) DO NOT mix with ZVW 237 105 (green) or any aftermarket antifreeze DOES NOT replace Part No: ZVW 237 105 (green) Regular antifreeze, Part No: ZVW 237 105: Color = Green DOES NOT replace and cannot be mixed with Part No: G 012 A8F A4 (purple) DOES NOT replace and cannot be mixed with Part No: ZVW 237 G12 (Pink) Follow coolant mixing instructions Cooling system - Service and Repair - Procedures - Draining and Filling, for the Model you are working on. Engine Coolant Coolant Type Type ..................................................................................................................................................... ................................................................... G12 (red) The coolant additives G11 (color: green) and G12 must never be mixed together. Mixing can cause serious engine damage. Page 1970 T 40001 - Puller Page 5307 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 2500 Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 2000->) Control Modules - Connector Pin-out Page 820 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 3141 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5426 <-- Place electrical connector -1- into ABS control module and push in direction of -arrow 2- <-- Lock electrical connector to ABS control module by pushing latch down -arrow 3^ If applicable, reinstall secondary air relay box and reinsert harness in support clip ^ If applicable, reconnect electrical connector to brake fluid reservoir <-- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) <-- If applicable reconnect air hose -4- from secondary air pump to air filter box -5<-- Reconnect vacuum line -7- to air box (TDI vehicles only) <-- Reconnect air intake hose to mass air flow sensor and secure with clamp -3<-- Reconnect electrical connector -1- to mass air flow sensor -2^ Reconnect the ground cable (GDN) from the negative (-) battery terminal ^ In the vehicle, remove brake pedal depressor from the brake pedal ^ Proceed to Section D Section D Section D - Code ABS Control Module ^ Connect VAS 5051 to data link connector located under dash left of steering column Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 1519 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 870 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Cooling System - Coolant Identification/Mixing Coolant: Technical Service Bulletins Cooling System - Coolant Identification/Mixing 19 10 03 March 18, 2010 2022548 Supersedes T.B. Group 19 number 10-02 dated March 17, 2010 to improve coolant table view. Condition Identifying and Mixing Factory Fill Engine Coolants Discontinuation and mixing of Volkswagen approved engine coolants. Technical Background Coolants G11, G12 and G12+ have been replaced by an improved version. New coolant G12++ will be introduced on all engines. Production Solution No production change required. Service. Identify which coolant the vehicle was filled with from the factory. The photo shows the color of each type of engine coolant. The table identifies which coolant can be added to the factory coolant. Tip: If a vehicle is found to have the incorrect coolant, the cooling system should be flushed using the repair manual procedures in Elsa Web and then filled with the correct coolant. Page 5460 Wheel Speed Sensor: Locations Left Rear ABS Wheel Speed Sensor G46 - Left Rear ABS Wheel Speed Sensor Page 2786 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 2900 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 1206 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor -G70-, item 4. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Page 2913 Vehicle Speed Sensor: Locations Vehicle Speed Sensor (VSS) G68 - Vehicle Speed Sensor (VSS) Page 3493 Wire Terminal Extractor used for ECU and ABS harnesses on 1998-2005 Jetta and Passat. The blade of the H 4673-9 has a width of 1mm. - Made in Germany - Easy to Use Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 6360 Display group 001 Display group 001, evaluating Page 627 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Page 2382 ^ Locate steering column multi-function switch connector on main harness. Vehicles with Multi-function (MFA) display ^ Replace brown/white wire of original harness at the windshield wiper multi-function switch connector T8c/3 with brown/white wire of fuel pump overlay harness. ^ Tape all reworked areas using velour tape. ^ Reassemble instrument panel using a new replacement instrument cluster. Reinstall all trim. ^ Reinstall washer fluid container. ^ Reinstall battery as necessary. ^ Re-connect battery (GND) cable (NO person can be inside vehicle during this step). ^ Code -J533- "Gateway" and Immobilizer functions where applicable. ^ Code instrument cluster and adapt odometer (see Repair Manual Electrical Equipment OBD Group-01) for appropriate MY vehicle. Warranty Information only. Required Parts and Tools 1. Instrument cluster, coolant bottle and fuel pump/fuel sender. 2. Vehicles with Climatronic may require ambient temperature sensor replacement. (see Parts Dept. for correct Part No.) 3. Repair Kit, Part No: 1JM998001 contains: Tip: Page 5962 - Remove screw -1- and bolt -2- Lift starter up and out from transmission. Installing Installation is in reverse order of removal. Note all tightening torques specified in removal procedure. Page 671 Part 1 A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation A/C Pressure Switch F129 A/C Pressure Switch F129 F129 has three functions: Switches the A/C clutch N25 off when excessive refrigerant circuit pressure is present (e.g.: insufficient air flow over condenser or when overcharged). - Switches the A/C clutch N25 off when insufficient refrigerant circuit pressure is present (e.g.: when refrigerant has leaked out) - Switches on the second speed coolant fan V7 when refrigerant circuit pressure increases. Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. - A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Page 5371 With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 4340 Part 1 Page 3390 Body Control Module: Locations J393 - Central Control Module For Comfort System J393 - Central control module for comfort system Page 137 Door Control Module, Left And Right Rear Control Modules - Connector Pin-out Page 6346 This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Left Seat Belt Switch Seat Belt Buckle Switch: Locations Left Seat Belt Switch E24 - Left seat belt switch Page 4975 - Remove flange shaft cone-head bolt. - Remove flange shaft with spring. - Pull out seal. Notes: Do not damage sleeve, otherwise leaks Will occur. - Replace sleeve if damaged. Refer to Case, M/T. Installing - Drive seal into sleeve onto stop. Do not tilt seal. - Fill space between sealing lips with G 052 128 A1 grease. - Insert flange shaft. - Install cone-head bolt into flange shaft threaded piece. - Install left-hand drive shaft or attach right-hand drive shaft to flange shaft. - Install drive shaft protective cover if necessary. Page 1188 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 853 Ambient Temperature Sensor / Switch HVAC: Locations Fresh Air Intake Duct Temperature Sensor G89 - Fresh air intake duct temperature sensor Page 6536 - Disconnect electrical connector -1-. - With screwdriver, carefully unclip operating rod -2- from lever -arrow A-. - Remove bolts -3-. - Turn operating rod -2- and remove from flap motor -4-. - Remove flap motor. Installing and adjusting - Initiate Basic setting, function 04 See Climatronic, OBD. Page 1253 - Check wires between test box and 4-pin connector (to control module) for open circuit according to wiring diagram. Terminal 3 + socket 68 Terminal 4 + socket 69 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 5442 ^ Remove bolts from bracket for hydraulic unit (arrows). ^ Remove hydraulic unit with control module. ABS control module, removing from hydraulic unit ^ Disconnect electrical connector for hydraulic pump motor from control module. ^ Remove bolts (arrows) from control module and remove control module. Notes: ^ When removing the control module make sure that the hydraulic unit valve dome does not contact the control module solenoid valves. ^ Cover the control module magnet coils with a plastic cover. Do not use rags. ^ After separating the control module and hydraulic unit use transportation protection for the valve dome. Installing Notes: ^ Only remove the sealing plugs on the new hydraulic unit just before installing the corresponding brake line. ^ If the sealing plugs are removed from the hydraulic unit too early, brake fluid can escape. It can then no longer be guaranteed the unit is sufficiently filled or adequately bled. ^ When assembling the control module and hydraulic unit, be sure that the hydraulic unit valve dome does not come in contact with the control module solenoid valves. ^ Using new bolts, install control module to hydraulic unit. Do not tighten more than maximum 4 Nm (35 inch lbs.). Page 623 Control Module: Locations J217 - Transmission Control Module (TCM) Page 2273 Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): - Check Fuel Pump (FP) current draw as follows: - Reconnect all disconnected fuel lines. - Connect multimeter with electrical current probe to wire of 4-pin connector (terminal 1 arrow) from wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max: 8 amperes NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2787 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 1061 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3813 Leak Detection Pump: Testing and Inspection With Manufacturer's Scan Tool Leak Detection Pump (V144) For Fuel System, Checking Special tools, equipment, test and inspection devices; required accessories - VAG1526 A hand-held multimeter - VAG1527 B voltage tester - VAG1594 A auxiliary measuring tool set - VAG 1598/31 adapter cable - Wiring diagram Checking power supply Test conditions Page 3726 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (6 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (6 spd. Manual transmission) Page 6539 Air Door Actuator / Motor: Service and Repair Temperature Flap Motor -V68-, Removing and Installing Temperature flap motor -V68-, removing and installing First do the following: - Remove glove box. - Remove trim under steering column. - Remove center console. Removing - Disconnect electrical connector -1-. - With screwdriver, carefully unclip operating rod -2- from lever -arrow A-. - Remove screws -4-. - Remove flap motor -3-. Installing and adjusting - Initiate Basic setting, function 04 See Climatronic, OBD. Page 5035 Shifter M/T: Service and Repair Selector Lever Removing and Installing 5 Speed Manual 02J Selector Mechanism, Removing And Installing Removing - Remove balance weight -A- and gear selector cable -B- from gear selector lever. - Remove gear selector cable together with washer and square nut (self-locking). - Lift lug in direction of arrow and pull gate selector cable off actuating arm/relay lever -C- Remove cable support bracket from transmission (arrows). If necessary unclip hose at cable support bracket first. Page 1116 Removal and installation is the same for all switches. ASR/ESP switch removal is described below: NOTE: Switches cannot be removed using a screwdriver due to the strong springs in their engagement mechanisms. Removing - First remove driver's side heated seat control module/regulator. - Reach behind the ESP switch using the tip of assembly tool T10034. - Release the button for ESP -1- using assembly tool T10034 and remove from vent. - Disengage and disconnect electrical harness connectors. - Remove emergency flasher switch -2- and switch for heated rear window -3- in the same manner if necessary. Installing - Connect and engage all electrical harness connectors. - Insert switches into vent and engage. With Manufacturer's Scan Tool Engine Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Engine Speed (RPM) Sensor -G28-, Checking The engine speed (RPM) sensor -G28- is a speed and reference mark sensor. The engine will not start if there is no speed signal. If the speed signal fails when the engine is running, it will cause the engine to stall immediately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test sequence - Disconnect grey 3-pin harness connector (arrow) from engine speed sensor. - Measure sensor resistance between terminals 2 + 3 of harness connector to sensor. Specified value: 480-1000 ohms - Check sensor for short between terminals 1 + 2 as well as -1- + -3-. Specified value: infinity ohms If the specified values are not obtained: - Replace engine speed (RPM) sensor -G28-, item 25. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 5811 ^ Over the counter (after market) parts. When testing or charging a battery either installed or removed from vehicle select appropriate battery type: ^ Select "Standard" (Lead-Acid) function for ALL NON-AGM batteries. ^ Select "AGM"function for Absorbent Glass Mat (AGM) batteries with "AGM" on battery label. Always use actual DIN rating as shown on battery label -arrow-. Tip: Label shown is for example only. DIN or SAE specifications may vary from battery to battery. If DIN rating is not shown: ^ Use SAE value as printed on the battery label. If using SAE value rating: ^ Midtronics tester menu option must be changed to achieve accurate results. ^ A change from DIN to SAE can be made from the "Other" menu option on Midtronics tester. 2-2 B6 Passat, Passat Wagon and CC with 3.6L 2006-2010 (Rear Battery) Testing/Charging at Battery Tip: DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions: ^ Battery was removed for a separate repair prior to performing battery test. ^ Over the counter (after market) parts. B6 Passat Sedan, CC, 3.6L only 2006-2010: ^ Select Lead Acid Battery for 3.6L engine (located in left side of trunk). 450 DIN. B6 Passat Wagon 3.6L only 2006-2008: ^ Select AGM (Absorbed Glass Mat) for 3.6L engine (located in left side of trunk). 480 DIN or 520 DIN. When testing or charging battery installed in vehicle: ^ DO NOT Test/Charge from Remote Location. Page 3380 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor Before TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control Before TWC, Checking, With Manufacturer's Scan Tool. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control Before TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. Specifications Water Pump: Specifications Coolant Retaining screws 15 Nm Page 468 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 135 J388 - Door control module, rear, left Door Control Module, Rear, Right J389 - Door control module, rear, right 4 Speed 01M Transmission Fluid - A/T: Service and Repair 4 Speed 01M Transmission ATF, Replacing - Remove sound insulation tray. - Remove sound insulation from left front longitudinal member. - Place container under transmission. - Remove ATF level plug from transmission oil pan. - Remove overflow pipe (2) through level hole. - Drain ATF. - Install overflow pipe. - Screw level plug in hand-tight. - Fill with 3 liters of ATF through filler pipe using VAG 1924. - Start engine and shift through all selector lever positions with vehicle stationary. - Check and top off ATF level. Page 5812 ^ (3.6L) DO NOT use remote location (+) - arrow-. ^ (3.6L) DO NOT use engine bracket (-) arrow-. Always use actual DIN rating as shown on battery label: ^ (3.6L) Test/charge battery located in left rear trunk -arrow-. ^ Passat Sedan / Passat CC 3.6L uses a lead acid battery 450 DIN. ^ Passat Wagon 3.6L uses an AGM battery. 480 or 520 DIN. 2-3 Eos 3.2L 2006 - 2008 Testing/Charging at Battery (Two 6-Volt batteries) Eos 3.2L engine is equipped with two 6-volt AGM batteries which are connected in series to achieve 12-volts. The battery system must always be treated as a 12-volt battery system. Never attempt to charge only one 6-volt battery. If battery replacement is necessary, never replace one 6-volt battery; both batteries must be replaced as a pair! Page 1958 Camshaft Gear/Sprocket: Tools and Equipment Puller Claw for VW 2.0 Turbo; Accessory Arm AST Tool # T 40001-7 Puller Claw for VW 2.0 Turbo; Accessory Arm AST tool# T 40001-7 Puller Claw - Accessory Arm used in conjunction with T 40001 Puller and T 40001-6 Arm. (Not part of the T 40001 kit; order separately.) Applicable to: VW/Audi: 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT); Used to remove Camshaft Gear / Wheel. - Made in Germany - Contact AST for pricing - Applicable; VW/Audi 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT) - Thin finger on end of Claw to fit into the tight area behind the Cam Wheel Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 6003 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 4055 If there is no malfunction in voltage supply: - Check activation. Checking activation - Using adapter cables, connect voltage tester (VAG1527) to Terminals 4 + engine Ground (GND) of disconnected connector for cylinder 1. - Operate starter and test ignition signal from Engine Control Module(ECM) LED should flicker. - Repeat test at connectors for fuel injectors 2 through 6. - Switch ignition off. If LED flickers and voltage supply is OK: - Replace respective ignition coil with power output stage, item 2 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If LED does not flicker: - Check wires. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Page 1896 Special tools, testers and auxiliary items required ^ Torque wrench V.A.G. 1331 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A. G141 0 Note: ^ If a vehicle that has an axle shaft removed is to be moved, an outer CV joint must be installed in place of the axle shaft and be tightened to 50 Nm (37 ft. lbs.) otherwise the wheel bearing will be damaged. ^ Welding and straightening operations are not permitted on load-bearing or wheel-controlling suspension components. ^ Always replace self-locking nuts. ^ Always replaced corroded nuts/bolts Locations Service Precautions Starter Motor: Service Precautions Starter CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Page 3415 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Measure resistance from throttle valve drive between terminals -3- and -5- Specified value: 1.0-5.0 ohms If the specified value is not obtained: - Replace throttle valve control module - J338- , item 10. Refer to "Intake Manifold Upper Section, Disassembling and Assembling" under "Fuel Delivery and Air Induction/Variable Induction System", - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt Engine Control Module (ECM) to throttle valve control module. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check accelerator pedal sensor. If the voltage supply and wiring is OK: - Replace Engine Control Module (ECM). Checking voltage supply and wiring to control module Page 4726 - Fit selector lever cable -1- in retainer -arrow- on engine. - Loosen bolt -2- at front ball socket of selector lever cable -1-. - Place selector lever cable in support bracket/transmission and push onto lever/selector shaft -4using a pair of pliers. - Fit new circlip -3- to selector lever cable at support bracket/transmission. - Carefully position frame on four corners -arrows- and lock in. Page 390 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 4790 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Engine - Rattling Noise On Start Up (Normal Condition) Variable Valve Timing Actuator: Technical Service Bulletins Engine - Rattling Noise On Start Up (Normal Condition) Condition Camshaft Chain Tensioner(s) or Camshaft Adjuster(s), Rattle or Knocking Noise 15 06 01 Oct. 24, 2006 2012988 Technical Background The camshaft adjustment is hydraulically actuated and controlled by the engine oil pressure. If the vehicle has been sitting, with the engine turned off for a period of time, the oil accumulation inside the camshaft adjusters partially bleeds off and the oil flows back into the oil sump. To ensure an efficient camshaft adjustment after an engine cold start, the oil pressure inside the camshaft adjusters must be built up as quickly as possible. During this time a slight rattle or knocking noise may be audible. This noise is normal at engine start and will last until the oil pressure is fully reinstated. Production Solution No production change required. Service DO NOT replace the Camshaft Tensioner(s) or Camshaft Adjuster(s) for the noise concern as described above. Tip: Replacing the Camshaft Tensioner(s) or Camshaft Adjuster(s) will not eliminate this noise. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Always see ETKA for the latest part(s) information. Page 3924 Fuel Pressure Check Valve: Testing and Inspection With Generic Scan Tool Check Fuel Pump (FP) Check-Valve. Test requirements - VAG1348/3A remote control is still connected. - VAG1318 pressure gauge is still connected. Test sequence NOTE: This test also checks the connections of the fuel supply line from Fuel Pump (FP) unit to connection point of pressure gauge for proper seal. - Close pressure gauge shut-off valve (lever perpendicular to direction of flow -position B-). - Operate remote control in short intervals until a positive pressure of approx. 3 bar has built up. - If excess pressure is built up, reduce pressure by carefully opening shut-off valve. WARNING: Danger of spray when opening shut-off valve. Hold container in front of open connection on pressure gauge. - Observe pressure drop on pressure gauge. Pressure must not fall below 2.5 bar within 10 minutes. If pressure drops further: - Check line connections for proper seal. If no malfunctions are found in wires: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Service and Repair Exhaust Pipe: Service and Repair For information on this component and the system it is a part of refer to Vehicle/Exhaust System/Service and Repair. Page 4935 - Remove brake carrier with brake caliper. To do this remove brake caliper and hang up with wire or similar. - Mark installation position of bolts from ball joint to control arm. - Remove bolts - arrows - . - Press axle shaft out. Note: When pressing axle shaft out ensure sufficient clearance is available. - Pull wheel bearing housing with ball joint out from control arm. - Remove axle shaft from wheel bearing housing and tie up. - The axle shaft must not hang down! - The inner CV joint will be damaged through overflexing. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove cover plate. - Remove connecting link from control arm. - Release speed sensor wiring from suspension strut. Caution: Place engine/transmission jack V.A.G. 1383/A underneath (danger of accident from falling parts when removing the wheel hub and the wheel bearing). Pulling out wheel hub - Insert thrust bolts -1 - in wheel bearing housing. - Install support - 2 - piston cylinder - 3 - with pull rod and special nut - 4 - . - Hold tool firmly pull out wheel hub. Page 3165 Electronic Throttle Control Module: Testing and Inspection Throttle Valve Control Module J338, Checking With Generic Scan Tool Throttle Valve Control Module, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of throttle valve control module. Function The throttle valve activation occurs via an electric motor (throttle drive) in the throttle valve control module. It is activated by the Engine Control Module (ECM) according to specifications of the two sensors, Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-, function of the E-gas system. Components of Throttle Valve Control Module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for throttle drive (power accelerator actuation) -G188Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Throttle valve must not be damaged or dirty. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 17: Throttle valve position (absolute)." - Check specified value of throttle valve position (absolute) at idle stop: Page 486 - Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly. - Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop: - End diagnosis and switch ignition off. If specified values are not obtained: - Disconnect the 6-pin connector at the throttle valve control module (arrow). Check resistance - Measure resistance of Throttle drive (power accelerator actuation) -G186- in Throttle Valve Control Module -J338- between terminals 3 + 5 Specified value: 1.0...5.0 Ohm If specified value is not obtained: - Replace Throttle Valve Control Module -J338-: Door Control Module, Driver and Passenger Side Door Module: Locations Door Control Module, Driver and Passenger Side Door control module, driver- and passenger side Page 2562 Water Pump: Tools and Equipment Water Pump Wrench AST tool# VAG 1590 Water Pump Wrench. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 6574 Air Register: Service and Repair Passenger's Air Outlet, Removing Passenger's Air Outlet (Golf And Jetta), Removing - Insert small screwdriver between air outlet housing and instrument panel and gently pry air outlet housing out from opening. CAUTION! Be careful not to damage instrument panel when removing outlet. Protect instrument panel in area of trim with adhesive tape before removing. - Pull out air outlet Jetta only: - Remove glove box - Disconnect electrical connection for air outlet illumination. Page 6462 - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake drum. - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Page 236 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6362 Display group 002 Display group 002, evaluating Page 6193 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Front Wheel Bearing: Service and Repair Front Wheel Bearing, Servicing II - Wheel bearing, servicing Special tools, testers and auxiliary items required ^ Thrust plate VW401 ^ Punch VW407 ^ Punch VW408A ^ Punch VW412 ^ Thrust tube VW432 ^ Thrust tube VW442 Page 6502 1 - Thrust bolt E-15 2 - Support E-40 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod 5 - High pressure hose with quick release coupling Pulling out wheel bearing - Remove circlip. - Install press piece - 1 - with shoulder to bearing, press sleeve - 2 - with four stepped internal diameters to wheel bearing housing, piston cylinder - 3 - with pull rod and special nut - 4 - . - Operate pump and remove the wheel bearing. 1 - Thrust tube E-5 2 - Press sleeve E-65-1 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod Pulling off bearing inner race from hub Pressing in wheel bearing - Clean hole from wheel bearing housing Page 4455 - Insert dial gauge -A- and zero with a preload of 1 mm. Move drive pinion up and down. Read play at dial gauge and note (example: 0.93 mm). Determining shims The specified bearing preload is achieved if the reading (0.93 mm), the preload of the bearings 0.12 mm and the amount for compression 0.10 mm are deducted from the 2 x 1.5 mm thick shims. Example: - Remove output gear. Determine size of shim on basis of table and fit onto drive pinion. - Re-install output gear, tighten hex nut to 250 Nm and secure with drift. Page 6431 - Insert special tool 3424 in slot (arrow). - Turn ratchet handle 90 and remove 3424. - Press brake disc toward strut by hand. Otherwise shock absorber tube could catch in wheel bearing housing hole. - Pull wheel bearing housing off shock absorber, downward. Remove upper shock absorber mount nut 1. Commercially available ratchet handle 2. T 10001/8 3. T 10001/11 4. T 10001/5 Page 3541 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 4707 - Tighten both bolts -arrows B- to 25 Nm. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Reconnect Ground strap to battery. - Check selector mechanism. - Enter radio code. Specifications Piston Ring: Specifications Piston ring Joint clearance Plain copression ring New 0.20 - 0.40 mm Plain Compression ring Max. wear 1.0 mm Tapered compression ring New 0.20 - 0.40 mm Tapered compression ring Max. wear 1.0 mm Oil ring New 0.25 - 0.50 mm Oil Ring Max. wear 1.0 mm Side clearance New Plain Compression ring 0.04 - 0.90 mm Tapered compression Ring 0.03 - 0.060 mm Oil ring 0.02 - 0.06 mm Side clearance Max. wear Plain compression ring 0.15 mm Tapered Compression ring 0.15 mm Oil ring 0.15 mm Page 4099 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 2337 Page 2149 states: Ignition ON, engine stopped, oil pressure switch closed - Engine speed above 1500/min, oil pressure switch open Note: The indicator light is not switched off if the engine speed exceeds 5000 rpm, not even if the oil pressure switch is closed. The indicator light will be shut off again when the engine speed drops below 5000 rpm. - If the oil pressure switch is only opened for 0.5 - 3.0 seconds when the engine speed is over 1500 rpm, this fact will be stored in the instrument cluster processor. If this state occurs three times while the engine is running, the warning will be triggered and will not be cleared even under 500 rpm. The warning will be cleared when the oil pressure switch is closed for more than 5 seconds and the ignition is turned off Test conditions - Oil level OK. - Indicator lamp for oil pressure (K3) must illuminate for approx. 3 seconds after the ignition is turned on. - Oil temperature at least 80°C Oil pressure switch, checking - Remove 1.4 bar oil pressure switch (F1) (black insulation) and screw it into tester. - Screw tester into oil filter housing in place of oil pressure switch. - Ground tester brown lead (-). - Connect VAG 1527 B diode test lamp to battery positive terminal (+) and to oil pressure switch using the auxiliary cables from VAG 1594 A. Light-emitting diode (LED) should not illuminate. If the LED illuminates: Replace 1.4 bar oil pressure switch (F1) If the LED does not illuminate: Start engine and let idle. Light-emitting diode should light at 1.2 - 1.6 bar. Otherwise, replace 1.4 bar oil pressure switch F1). Oil pressure, checking Test condition - The VAG 1342 oil pressure test instrument is not connected - Oil temperature at least 80 0 C Test sequence - Start engine and let it idle. Specification: oil pressure: at least 2.0 bar Increase engine speed. The oil should be at least 2.0 bar at 2000 rpm and 80° C oil temperature. - The oil pressure may not exceed 7.0 bar - Replace oil pump if necessary. Description and Operation Electronic Throttle Control Module: Description and Operation Function of the Electronic Throttle Control System In the electronic throttle control system, the throttle valve is not actuated by a cable from the accelerator. There is no mechanical connection between the accelerator and throttle valve. The accelerator position is communicated to the engine control module by two throttle position sensors (variable resistance, accommodated in a casing), which are connected to the accelerator. The accelerator position (determined by the driver) is a main input variable for the engine control module. An electric motor (throttle actuator) in the throttle valve control module -J338- actuates the throttle valve over the entire range of engine speeds and load. The throttle valve is actuated by the throttle actuator under instructions from the engine control module. When the engine is off and the ignition is turned on, the engine control module controls the throttle actuator precisely, following specifications from the throttle position sensor. That is, if the accelerator is half-way to the floor, then the throttle actuator opens the throttle valve to the same angle; the throttle valve is then opened approximately half-way. When the engine is running (under load), the engine control module can open or close the throttle valve independently of the sensor. As an example, the throttle valve can already be completely open, even though the accelerator has only been pressed half-way down so far. This has the advantage of preventing throttling loss at the throttle valve. Under certain load conditions, this also results in significantly reduced emissions and improved fuel consumption. It is wrong to believe that electronic throttle control only consists of two components. It is a system which contains all components needed to help determine, regulate, and supervise the throttle valve position (e.g. the throttle position sensor which measures the accelerator position, the throttle valve control module, the EPC indicator lamp, the engine control module). Page 5157 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 669 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 632 Test Step 7 - 15 Page 2641 - Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 12. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-. See: Computers and Control Systems/Sensors and Switches - Computers and Control Systems/Throttle Position Sensor/Testing and Inspection If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Checking voltage supply and wiring to control module - Connect multimeter to connector terminals 2 + 6 for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. - Connect test box to control module wiring harness connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram: Terminal 1 + socket 92 Terminal 2 + socket 83 Terminal 3 + socket 117 Terminal 4 + socket 84 Terminal 5 + socket 118 Terminal 6 + socket 91 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm Page 6500 Special tools, testers and auxiliary items required ^ Hydraulic removal and installing tool for wheel bearing V.A.G. 1459 B ^ Piston cylinder HKZ-15 with hydraulic press piece E0-204-T ^ Removal rods E-0-217+218 ^ Special nut E-8-214 Thrust tube E-5 ^ Thrust tube E-10 ^ Press sleeve E-13-1 ^ Thrust bolt E-15 ^ Supplementary set V.A.G. 1459 B/2 ^ Bell E-40 - Lift vehicle until the load on the front axle is relieved. - Loosen 12-point nut. - Lift vehicle to installing height. - Remove wheel. The following three work steps are necessary only for vehicles with modified stabilizer bar mounting. - Loosen upper hex nuts of connecting links from left and right suspension strut. - Pull out clamp on brake hose bracket and release brake hose. - Release speed sensor wiring from front suspension strut. Page 2695 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 4671 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide Page 1820 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Ball Joint, Inspection Ball Joint: Specifications Ball joint radial play No visual play Ball joint Axial play No visual play Page 2412 Page 2422 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 4023 - Disconnect vacuum hose -1- from Intake Manifold Tuning (IMT) valve - N156- -2-. - Connect VAG1390 hand vacuum pump to Intake Manifold Tuning (IMT) valve -N156- -2-. - Perform output Diagnostic Test Mode (DTM) again. When Intake Manifold Tuning (IMT) valve -N156- is activated, operate hand pump uniformly. The positioning element must switch back and forth between the two positions. If the change-over does not function as described: - Check change-over mechanical components for ease of movement (move rods by hand). - Check that vacuum hoses are connected correctly. - Check vacuum system, including vacuum reservoir. NOTE: The vacuum reservoir is bolted to the sump on the left-side, next to the oil filter. Page 241 Specifications Wheel Fastener: Specifications Wheel bolts to wheel hub for all vehicles ............................................................................................................................................ 120 Nm (88 5 ft. lbs.) Bonded Rubber Bushings For Sub-Frame, Removing and Installing Subframe: Service and Repair Bonded Rubber Bushings For Sub-Frame, Removing and Installing Bonded rubber bushings for subframe, removing and installing Special Tools and equipment ^ VW 408A Press tool ^ 3347 Tube ^ VW 402 Thrust plate Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module: Service and Repair Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation Adaptation teaches the Engine Control Module (ECM) (with ignition switched on and engine not running) the throttle valve control module stop positions and a comparison graph between throttle valve potentiometer and throttle position sensor. Adapting sequence must be performed if: - The voltage supply is interrupted - The throttle valve control module is removed and installed - The throttle valve control module is replaced - If when installing another engine another throttle valve control module is installed Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - No DTCs stored in DTC memory. - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - Throttle valve must be at idle speed position Work sequence Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select data function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -6- and -0- to input display group number 60 (060) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 60 -> 1234 After pressing the -Q- button, the throttle valve position sensor is switched so that it is not supplied with voltage at the start of the test. In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in the throttle valve control module. The values that both angle sensors provide in the emergency running position are stored by the Engine Control Module (ECM). Thereafter, the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle valve to the previously learned emergency running position within a predetermined period (spring test). Then the throttle valve is closed by the throttle valve positioner, and the values, which are supplied by the angle sensors in the throttle valve control module, are stored by the Engine Control Module (ECM). If the Engine Control Module (ECM) switches the throttle valve position sensor so that it is without voltage during normal operation, it is indicated by an increased and varying idle. The engine reacts slowly to accelerator changes. - Check specified values (display fields 1-4): Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2958 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 4943 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Raise vehicle. - Remove wheel. - Reset brake - To do this use a screwdriver through the opening in brake drum and push adjuster upward. - Remove phillips-head screw for brake drum and take out brake drum. - Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove 12-point nut. Page 4633 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 4717 10. Locking segment - Place on centralizing elements of selector lever housing -item 1611. Plate 12. Locating spring with roller - Locates in the detent in selector lever -item 1313. Selector lever - With pull rod, spring, detent, contact spring for selector lever position and releasing locking cable 14. Roller 15. Circlip 16. Selector lever housing - Need not be removed to replace the majority of individual parts, with the exception of selector lever and selector lever lock solenoid 17. Fulcrum pin - Splined - Grease shank - Do not turn when installing selector lever 18. Bolt, 25 Nm 19. Locking lever - For locking cable - For locking in selector lever position p 20. Shim 21. Bolt 22. Gasket - Always replace 23. Cover - For selector lever housing 24. Bolt - Qty. 14 25. O-ring - Always replace 26. Bolt, 8 Nm - Qty. 2 27. Contact spring - For selector lever position display 28. Bolt, 4 Nm - Place selector lever in to loosen and tighten 29. Clip 30. Steering lock 31. Bolt - Qty. 2 - Solenoid to selector lever housing 32. Shift lock solenoid -N110- Removing and installing - Can be checked in electrical test and in measured value block - Only remove and install with selector lever in position "1" - Note positions of spring and locking pin when removing - Remove together with locking pin and spring, and when doing this move selector lever back and forth slightly - Route wiring with sufficient clearance to selector lever 33. Cable tie - Wiring/solenoid to selector lever housing - Always replace 34. Spring 35. Locking pin 36. Nut, 13 Nm - Always replace 37. Washer 38. Nut, 25 Nm - Qty. 2 - Always replace 39. Locking cable - For ignition key removal lock - Must not be kinked - Checking operation of the ignition key withdrawal lock. 40. Circlip - Always replace - For mounting selector lever cable to selector lever housing - Install with angled end inside selector housing Page 5095 Test Step 5 - 6 Page 909 Checking - Switch ignition on. - Press button (arrow) for Duty Cycle measurement (modulation ratio) on ignition tester VAG 1767. Test results, evaluating NOTE: If a malfunction cannot be located, check DTC memory of Engine Control Module (ECM) and the Transmission Control Module (TCM) using VAG 1551/1552 Scan Tool. When doing so, note that DTCs related to high pressure sensor -G65- functions may be called-out as "A/C pressure switch -F129". Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Page 338 Page 2871 - Check resistance for sensor heater at connector to oxygen sensor terminal 3 + 4. - Specified value: 2.5...10.0 Ohm (at room temperature) If specified value is not obtained: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7. - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 4 + socket 5 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 6-pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4714 - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7- and remove. Note contact spring for selector lever position display! - Remove front selector mechanism securing nuts (Qty. 2). - Pull selector lever cable -1- upward off lever/selector shaft -4-. - Remove circlip -3- at support bracket. - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove cover from selector lever housing. Page 5019 I Removing and installing selector lever and boot II - Servicing gear lever and gear lever housing III - Assembly overview: Removing and installing operating cables Removing and installing selector mechanism. Adjusting selector mechanism. Note: Before working on the selector mechanism, disconnect ground strap from battery in engine compartment. - Note radio code on vehicles with coded radio. Special tools and equipment required Page 3907 - Connect diode test lamp to connector of fuel injector to be tested terminal 1 and Ground (GND). Vehicles with engine code BDF - Connect diode test lamp to connector of fuel injector to be tested terminal 1 and Ground (GND). Continuation for all vehicles - Operate starter and test voltage supply for fuel injector. LED must light up. - Switch ignition off. If LED does not light up: - Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Activation and voltage supply, checking Vehicles with engine code AFP - Connect diode test lamp to the connector terminals of the fuel injector to be checked. Vehicles with engine code BDF Page 5980 Part 2 Page 5428 Use only Volkswagen approved brake fluid CAUTION! BRAKE FLUID IS POISONOUS. BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. ^ Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper ^ With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw ^ Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle ^ Ensure that brake fluid in the reservoir is at the correct level ^ Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 1601 Clay St., Detroit, MI 48211 ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL! Locations Radiator Cooling Fan Control Module: Locations J293 Coolant Fan Control (FC) control module - engine compartment, lower left, below front longmember Page 4660 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5989 Relay Arrangements On The Relay Panel Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Fuse Arrangements In Fuse Bracket/Battery Page 2041 Upper intake manifold to support at cylinder head 25 Nm Page 3545 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid Capacity ............................................................................................................................................... .................. 0.7 to 0.9 liter (0.74 to 0.95 quarts) Hydraulic Oil ........................................................................................................................................ ...................................... part number G 002 000 Note: Do not use ATF Page 3903 - Check resistance of fuel injectors between terminals. Specified value: 13.0-19.0 ohms NOTE: The resistance figures are valid for approx. 20 °C. At higher temperatures the resistance figures will increase. If the specified value is not obtained: - Replace faulty fuel injector, item 12. Refer to "Intake Manifold Lower Section, Disassembling and Assembling", Pay attention to the following when installing the fuel injector: - Replace O-rings on all fuel injectors and lightly moisten with clean engine oil. - Insert fuel injectors vertically and in the correct position into the fuel rail and secure using retaining clips. - Fit fuel rail with fuel injectors installed and secured on intake manifold lower section and press in evenly. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory2. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking voltage supply - Connect voltage tester to terminal -1- and Ground of relevant fuel injector harness connector. - Operate starter and check voltage supply for fuel injector. The LED must light up. If the LED does not light up: - Switch ignition off. - Check wire between 2-pin harness connector terminal -1- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms Page 2212 - Remove bolts - arrows - from lower timing chain case. - Remove lower timing chain case cover. CAUTION: Do not damage Cylinder Head Gasket, when removing timing covers. Page 746 Sunroof / Moonroof Switch: Service and Repair Automatic Rotary Switch For Sunroof, Removing (Webasto) Automatic Rotary Switch For Sunroof Removing - Unclip trim - 1 - in direction of - arrow - and remove. - Remove bolts - arrows - and remove automatic rotary switch. - Unclip and disconnect connector. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Front Axle Nut: Specifications Front Vehicles with 12-point nut Tighten 12-point nut to 200 Nm (147.5 ft lb) and then loosen 1/2 turn. Turn hub 180°. Tighten 12 point nut to 50 Nm (37 ft lb) plus an additional 60° turn. Vehicles with hex bolt Tighten hex bolt to 250 Nm (184.4 ft lb) and an additional 90° turn and then loosen 1/2 turn. Turn hub 180°. Then finally tighten to 250 Nm (184.4 ft lb) plus additional 90° turn. To tighten 12-point nut/hex bolt we recommend the angle measuring wrench VAG 1756. NOTE: If an angle measuring wrench is not available, then tighten 12-point nut using following method: - Lower vehicle until the wheels touch ground. - Tighten 12-point nut to 200 Nm (148 ft lb) and then loosen 1/2 turn (180°). - Tighten 12-point nut to 50 Nm (37 ft lb). Page 644 Test Step 12 Page 3783 Catalytic Converter: Application and ID Oxygen Sensor and Catalyst Configuration Example V6/V8/V12 Engine W/2 Exhaust Banks & 4 Catalysts V6/V8/V12 Engine W/2 Exhaust Banks & 3 Catalysts L4 Engine W/1 Exhaust Banks & 2 Catalysts Page 6575 Air Register: Service and Repair Side Window Air Outlet, Removing Side window air outlet, removing - Carefully pull out using needle nose pliers Recall 04V584000: Hazard Switch/Relay Replacement Hazard Flasher Relay: Recalls Recall 04V584000: Hazard Switch/Relay Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 2000-2002 Volkswagen/GTI 2000-2002 Volkswagen/Jetta 2000-2002 Manufacturer: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 04V584000 RECALL DATE: Dec 13, 2004 COMPONENT: Exterior Lighting: Hazard Flashing Warning Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 350000 SUMMARY: On certain passenger vehicles, the hazard switch and flasher system function may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays which occurs due to substantially increased electrical current load from higher wattage turn signal bulbs. CONSEQUENCE: This may result in intermittent or inoperative turn signal and hazard flasher function. REMEDY: Dealers will replace the hazard flasher switch/relay kit. The recall is expected to begin during february 2005. Owners should contact Volkswagen at 1-800-822-8987. NOTES: VW recall No. VX. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 4806 - Test-drive vehicle and inspect transmission for signs of leakage. Page 6537 Air Door Actuator / Motor: Service and Repair Footwell/Defrost Flap Motor -V85-, Removing and Installing Footwell/defrost flap motor -V85-, removing and installing Removing - Remove trim under steering column. - Disconnect electrical connector -1-. - Turn flap motor -4- and disengage from operating rod -2-. - Remove flap motor -4- from housing. Installing and adjusting - Initiate Basic setting, function 04 See Climatronic, OBD. Page 2632 Body Control Module: Connector Views Central Control Module For Comfort System; Power Sunroof Control Module Control Modules - Connector Pin-out Page 2104 Ca-Va Page 3688 - Use the wiring diagram to check the cables between the test box and the connector for any broken connections. ^ Contact 1 + cavity 72 ^ Contact 2+cavity 73 ^ Contact 3+cavity 36 ^ Contact 4+jack 35 ^ Contact 5+jack 33 ^ Contact 6+jack 34 ^ Line resistance: max. 1.5 0 - Also check the cables for a short circuit to the battery positive terminal or to ground. - Also check the cables for short circuits between each other. If no problems can be found in the cables: Replace the throttle position sensor (G79). Page 787 ^ Using a screwdriver, lift cover of multi-pin connector and remove. ^ Using a small screwdriver, push purple latch in direction of arrow. Pin assignment of harness connector T25 and ABS Control Module (W/EDL) -J104 Pin Connected to component: 19 + 20 Right Front ABS Wheel Speed Sensor -G45 1 + 2 Left Front ABS Wheel Speed Sensor -G47 Page 5242 Test Step 10 - 11 Page 3253 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no sensor malfunction is detected: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3- pin harness connector for open circuit according to wiring diagram. Terminal -1- + socket 108 - Terminal -2- + socket 90 - Terminal -3- + socket 82 - Wire resistance: max. 1.5 ohms - Additionally check wires for short to one another. If no malfunction is found in the wiring: - Remove sensor and check sensor wheel for secure fit, damage and run-out. NOTE: There is a larger gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If no malfunction is detected on sensor wheel: - Replace Engine Control Module (ECM). Page 4917 - Remove circlip 1. Pliers VW 161A or available commercially Place axle shaft. - Hold axle shaft, press triple roller star off shaft. - Remove triple roller star with roller and place on clean surface. - Remove CV joint from axle shaft. - Remove sleeve from axle shaft. - Clean shaft and CV joint. Assembling - Slide small clamp and boot for CV joint on shaft. - Slide CV joint on shaft. Assembling triple roller star Service and Repair Oil Spray Jet: Service and Repair For further information regarding this component please refer to Lubrication Systems; Service and Repair. Mechanical Diagrams Intake Manifold: Mechanical Diagrams Intake Manifold Upper Section Intake Manifold Upper Section, Disassembling and Assembling 1 - Intake manifold upper section 2 - Oil seal Always replace 3 - Bearing cap - For intake manifold change-over barrel 4 - 10 Nm (7 ft lb) 5 - 25 Nm (18 ft lb) 6 - Vacuum connection From Leak Detection Pump (LDP) -V1447 - Vacuum connection From fuel pressure regulator/non-return valve T-piece 8 - Vacuum connection From brake servo 9 - Vacuum connection From crankcase breather/Evaporative Emissions (EVAP) canister purge regulator valve -N80T-piece connecting hose 10 - Throttle valve control module -J338-* If replaced, perform engine control module adaptation. See: Powertrain Management/Computers and Control Systems/Engine Control Module/Testing and Inspection - No cable disc for accelerator cable as this is an electronic accelerator system - Harness connector contacts gold plated - Heated by coolant 11 - Ground wire 12 - Vacuum positioning element For Intake Manifold Tuning (IMT) valve -N156- Check. See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection 13 - To Intake Manifold Tuning (IMT) valve -N15614 - Bracket For engine cover 15 - Positioning lever For change-over barrel Page 3112 If the display does not change: - Disconnect 2-pin harness connector from clutch vacuum vent valve switch -F36-. - Measure resistance between switch terminals -1- and -2-. - Specified value without clutch depressed: max. 1.5 ohms - Specified value with clutch depressed: max. infinity ohms If the specified values are not obtained: - Replace clutch vacuum vent valve switch -F36-. NOTE: Observe installation position of clutch pedal switch in bearing bracket upper assembly hole. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased of the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified values are obtained: - Connect multimeter to measure voltage between terminal -1- and Ground (GND). - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring for open circuit between 2- pin harness connector terminal -1- and central electrics using wiring diagram. If the specified values are obtained: - Remove wiper arms and plenum chamber cover. Page 5044 - V.A.G 1331 Torque wrench - V.A.G 1275 Pliers Selector lever knob and boot, removing and installing 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 4063 and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 1830 Relay Arrangements On The Relay Panel Page 6457 Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove securing bolts - A - from brake caliper. - Remove brake caliper and hang up on body. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove 12-point nut. Page 6472 Axle Nut: Tools and Equipment VW/Audi Axle Nut Set AST tool# 6500 Page 5777 ^ Using extractor tool from wiring harness repair set VAS 1978, push out applicable terminals. ^ Disconnect wheel speed sensor wiring connector. ^ Replace faulty wheel speed sensor wiring. ^ Connect speed sensor to speed sensor wiring. ^ Secure speed sensor wiring (arrows). Note: Make sure the wiring is not twisted in the wheel well. ^ Install pin connectors in connector housing. ^ Using installation tool from VAS 1978, push individual wire seals to stop. ^ Secure terminals by engaging purple latch and install cover of multi-pin connector. Page 4945 - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake drum. - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Page 6331 Steering Wheel: Connector Locations Control Module For Multi-Function Steering Wheel Multi-pin Connector Assignments 1 - Comfort CAN Bus - Low 2 - Open 3 - Comfort CAN Bus - High 4 - Open 5 - Radio, serial data 6 - Data Link Connector (DLC) K-wire 7 - Cruise Control System (CCS) resume, accelerate 8 - CAN Bus Ground (GND) 9 - Open 10 - Ground (GND), terminal 31 11 - Double tone horn relay 12 - Terminal 15 13 - Terminal 30 14 - Open 15 - Terminal 58d 16 - Cruise Control System (CCS) + (SET/ delay) 17 - Heating inlet "ON" 18 - CAN Bus to Control module steering wheel -E221- Page 4909 Fig. 2 Inner CV joint, pressing off NOTE: Support ball hub while pressing off - Use drift to remove boot Fig. 3 Spring washer on inner joint, installation position 1. Spring washer Fig. 4 Spring washer and thrust washer on outer joint, installation position 1. Spring washer 2. Thrust washer Fig. 5 Inner CV joint, pressing on Specifications Thermostat: Specifications Thermostat Opening starts at approx. 80 degrees C Opening ends approx. 105 degrees C Total travel at least 7 mm Page 6524 6500 X-32 - 32mm, 12-Pt. Socket Page 5493 ^ Remove seal using wedge 3409. Note: When removing the piston seal make sure that the cylinder bore is not damaged. Installing ^ Thinly coat piston and piston seal with assembly lubricant G 052 150 A2 before inserting. ^ Place protective seal with outer sealing lip on piston. ^ Hold piston in front of caliper and insert inner sealing lip into groove in cylinder using wedge 3409. Page 4266 ^ ALL fault memories must be interrogated and erased. Note: Failure to erase ALL fault memories may cause "Update - Programming" (flashing) procedure to fail! - Select Diagnosis function 06 "End output". - Select Diagnosis function 00 "Collection services". - Select "Check DTC memory - complete system". which will interrogate all fault memories. - Erase ALL fault memories. Once ALL fault memories have been erased: - Select vehicle system "01-Engine electronics". - Select "Update - Programming" option at bottom of screen (arrow). CAUTION! Once "Update - Programming" function has been started, switching ignition OFF or disconnecting the diagnostic connector may completely destroy the ECM. "Update - Programming" (flashing), performing Page 2934 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Power Steering, Assembly Overview Power Steering Pump: Service and Repair Power Steering, Assembly Overview With Power Steering Pump In Lower Section 1. Bracket 2. Bolt ^ 25 Nm (18 ft. lbs.) 3. Banjo bolt ^ 30 Nm (22 ft. lbs.) 4. Pressure hose 5. Sealing ring ^ Always replace 6. Suction hose 7. Clamp 8. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 9. Belt pulley 10. Sockethead bolt ^ 25 Nm (18 ft. lbs.) 11. Ribbed belt Page 1756 Va-To Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2818 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Page 3816 - Disconnect 3-way plug from leak detection pump (V144) -arrow-. - Connect VAG 1526 A hand-held multimeter for measuring resistance between contacts 1 and 3 of leak detection pump. Specification: 640 - 720 Ohms. - Connect VAG 1526 A hand-held multimeter for measuring resistance between contacts 2 and 3 of leak detection pump. Specification: 12.5 - 19.5 Ohms. If the specifications were not attained: - Replace leak detection pump for fuel system (V144), item -8-. - Read-out readiness code: - If fault memory has been erased or engine control module was separated from positive voltage supply, readiness code must be regenerated: Page 1531 Rain Sensor: Service and Repair For removal and installation of interior mirror with Rain Sensor, please see Body and Frame/Mirrors. Page 3230 - Perform resistance measurement again between test box sockets 77 + 79: Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Terminal Resistance For CAN-Bus, Checking Function The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm If specified value is obtained (wires have no shorts): Component Locations Fuse Block: Component Locations Fuse Panel Location The fuse panel is located behind a cover on the driver side end panel of the instrument panel (dashboard). Page 516 Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Specifications Valve Clearance: Specifications Valve clearance Less than 0.2 mm more than 0.1 mm Page 1209 Intake Air Temperature Sensor: Testing and Inspection With Generic Scan Tool Intake Air Temperature (IAT) Sensor, Checking NOTE: The Intake Air Temperature (IAT) Sensor -G42- is a component of the Mass Air Flow (MAF) Sensor -G70- and cannot be replaced individually. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram - Chilling spray (commercially available) Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 15: Intake air temperature". - Check specified value of intake air temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which is below the ambient temperature of sensor, first check sensor wires for contact resistance. Note that while the vehicle is standing still the sensor might warm up due to radiant heat. If specified value is obtained: - Remove intake air hose between Mass Air Flow (MAF) sensor and throttle valve control module: Vehicles with engine code AFP, item 3, - Vehicles with engine code BDF, item 16. - Remember the intake air temperature value. Page 3654 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 791 ^ VAS 1978 Wiring harness repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery ^ Disconnect wheel speed sensor wiring connector. ^ Remove rear interior side Panel trim. ^ Strip insulation (arrow) from shrink connection. ^ Cut speed sensor wiring in front of spliced connection with stripping pliers from VAS 1978 wiring repair kit and remove faulty wiring. ^ Strip insulation at wiring end by 15 mm (5/8 inch) using stripping pliers from repair kit and fold over stripped wire portion. ^ install new speed sensor wiring. ^ Connect wheel speed sensor to speed sensor wiring. Page 5698 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 2381 ^ Place this spliced wire to the right of the steering column keeping wire out of the way. ^ Tape violet/red wire (from main harness back to harness). Tip: To eliminate confusion as wires are spliced, cut wire from position (22) of old connector near its base. ^ Locate the brown/white wire from position (7) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness (stop just short of the last splice connector). Tip: Remember, wire splices must be staggered to reduce the wire bundle size of the complete repair. ^ Cut both wires. Tip: To eliminate confusion as wires are spliced, cut wire from position (7) of old connector near its base. ^ Locate and strip brown/white wire from engine overlay harness. ^ Strip wire from position (7) of cluster overlay harness and twist together with brown/white wire from engine overlay harness. ^ Insert these two wires into a red splice, Part No: 111971940A and crimp. ^ Twist together the two brown/white wires from fuel pump/sender overlay harness. ^ Insert these two wires into the open end of the red splice connector and crimp. ^ Place these spliced wires to the right of the steering column keeping wire out of the way. With special connections to overlay harnesses now complete: ^ Locate wire in position (1) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness (stop just short of previous splice). Using a light yellow splice connector Part No: 111971941A: ^ Cut, strip and immediately splice wires. ^ Place this spliced wire to the right of the steering column keeping wire out of the way. Continue splicing wires in this fashion until all wires from original harness have been used. Any unused wires must be taped back to the harness. Page 975 Note: Make certain the brake light switch is installed with the wiring harness connector housing pointing upward. ^ Secure the brake light switch and plunger position by slowly turning the brake light switch full to the right (clockwise) 45 degrees, and the internal stop pin of the brake light switch is fully seated at the end of slot in outer shell. Tip: A click should be heard when the switch is turned to the correct position. This action also turns the plunger shoe into the correct position to make the correct electrical contacts in the switch operate as well as locks the plunger adjustment. ^ Internal stop pin (white arrow) of the brake light switch is fully seated at the end of the slot in the outer shell (black arrow) when brake light switch is correctly installed. ^ Reconnect brake light switch wiring harness connector. If the EPC or glow plug light was blinking and there was a diagnostic code (DTC) stored in the Engine Control Module and the DTC was related to the brake light switch: ^ Connect the VAS 5051/5052 to clear DTC. ^ Create engine readiness code. ^ Depress brake pedal to verify proper function and brake light operation. ^ Install cover under dashboard. Part return pertains to U.S. vehicles ONLY ^ When requested by WTC, return all brake light switches replaced to the address below. Include a copy of the repair order, all diagnostic printouts, and any other related documentation. Volkswagen of America, Inc. Warranty Test Center 3800 Hamlin Rd. - GE01 Auburn Hills, MI 48326 Page 3759 Secondary Air Injection (AIR) Pump Relay -J299-* (arrow) NOTE: - Remove battery Ground (GND) strap if tools are necessary for removal of relays or control modules from the relay carrier. - Obtain radio code for radios with anti-theft coding before disconnecting battery. - Check activation of the Secondary Air Injection (AIR) Pump Relay. - Vehicles with engine code BDF, see Fig. 1. Fig. 1 Relay position assignment in protective housing (engine compartment, left) 1 - Secondary Air Injection (AIR) Pump Relay -J299-* 2 - Motronic Engine Control Module (ECM) Power Supply Relay -J271-* NOTE: - Remove battery Ground (GND) strap if tools are necessary for removal of relays or control modules from the relay carrier. - Obtain radio code for radios with anti-theft coding before disconnecting battery. - Check relay activation. - Check wire between terminal 2 of relay carrier and terminal 2 of 2-pin connector of Secondary Air Injection (AIR) Pump Motor for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check the wire for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms Page 3308 Display Field 2 Programming and Relearning Gateway, Coding (function 07) When replacing the instrument cluster, the Data Bus On Board Diagnostic Interface -J533- must be coded according to vehicle equipment. NOTE: Coding must be performed regardless if the instrument cluster is new or has been previously coded (installed in a vehicle). Initiating coding - Press buttons -0- and -7- to select "Code Control Module", function 07. Indicated on display: Rapid data transfer Q 07 - Code control module - Press -Q- button to confirm input. Indicated on display: Code Control Module Enter code number XXXXX (0-32000) - Determine code number using code table below: Control Modules on "Powertrain" Code: CAN Bus Automatic transmission 00001 Anti-lock brake system (ABS) 00002 Airbag 00004 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 4865 - Fit retainer -A- to master cylinder operating rod -B-. - Press clutch pedal in direction of arrow to engage. Ensure correct location. - Fit stop -A- for clutch pedal again. Installation position: The arm (arrow) points toward master cylinder -B-. Bleeding clutch system after installing master cylinder. Page 3220 Page 1241 Display Group 030 Explanation of 3 digit number block in display field 2 Page 2559 Water Pump: Service and Repair Coolant pump, removing and installing (with engine installed) Special tools and equipment 10-222A Engine support bracket with legs 10222A/1 T10007 Refractometer VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 Nm) VAG 1332 Torque wrench (40...200 Nm) VAG 1590 Coolant pump wrench VAS 5024 Assembly tool for spring-type clips VAS 5085 Ladder Page 4024 Variable Induction Control Valve: Testing and Inspection With Generic Scan Tool Intake Manifold Change-over Valve, Checking Solenoid valve is closed when no voltage is present. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Intake Manifold Change-Over Valve -N156- must be OK: - Ignition switched off. Test sequence Vehicles with engine code AFP - Disconnect 2-pin connector from Intake Manifold Change-Over Valve -N156- (arrow). Vehicles with engine code BDF - Disconnect 2-pin connector from Intake Manifold Change-Over Valve -N156- (arrow). Page 2316 Water Pump: Testing and Inspection Coolant feed pump (V51), checking Special tools, equipment, test and inspection devices; required accessories - VAG 1527 B Voltage tester - VAG 1594 A auxiliary measuring tool set Test conditions - Fuse # 16 OK Test sequence - Disconnect two-way connector from coolant feed pump -V51-. Page 6358 Indicated on display: Output Diagnostic Test Mode -> END - Press -> button. Indicated on display: Rapid data transfer HELP Select function XX - End Output (function 06). Reading Read Measuring Value Block (Function 08) On Board Diagnostic (OBD) continually monitors the input signals and voltages required to operate the steering wheel electronics. Use this function to observe various multi-function steering wheel system inputs. The measuring value block is divided into 2 display groups, each containing up to 4 display fields. - Connect VAG 1551 Scan Tool (ST), input address word 16, "Steering - wheel electronics", and press -> button until "Select function XX" appears in display. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display: Rapid data transfer Q 08 - Read Measuring Valve Block - Press -Q- button to confirm input. Indicated on display: Read Measuring Value Block HELP Enter display group number XXX - Using the Scan Tool (ST) button pad, enter required display group number (following example shows display group 001). Press keys 0, 0 and 1 for "Display group number 1" and press -Qbutton to confirm input. Indicated on display: (1...4 = Display zones) Read Measuring Value Block 1 -> 1234 Page 5915 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. Page 5926 ^ Take a sharp awl and put a hole into emblem on the point shown. Tip: Apply gentle pressure on the awl while using a circular motion to pierce through emblem. Once through surface: ^ Tilt awl at a 45 degrees angle. ^ Pry back till emblem comes off. EMBLEM INSTALLATION Attach new emblem Part No: 3B0 837 891 09Z, with a small drop of 3M quick fix adhesive Part No: 08155. Tip: Fold over a piece of tape, sticky side out and place on logo side of emblem. This helps to line up emblem correctly on the key. Page 6455 Wheel Bearing: Service and Repair Rear Wheel Bearings, Servicing Wheel bearings, servicing Wheel bearings, vehicles with front wheel drive, servicing Note: The descriptions and illustrations are for vehicles with disc brakes. - Wheel fittings for vehicles with drum brakes is the same. - All tightening torques and notes are therefore valid for vehicles with drum brakes. 1. Phillips-head screw 2. Brake disc 3. Dust cap - Always replace A perfect seal is only achieved using a new dust cap. Only then is an optimum function and long service life guaranteed. 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace 5. Wheel hub with wheel bearings The wheel bearing and wheel hub are installed together in housing. This wheel bearing/hub unit is maintenance and adjustment free. Adjusting and servicing is not possible! 6. Axle beam Page 4554 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 5161 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Testing and Inspection Throttle Body: Testing and Inspection Components of the throttle valve control module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1- for for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for for throttle drive (power accelerator actuation) -G188NOTES: - If the throttle valve control module is replaced, the new control module must be matched to the Engine Control Module (ECM). See: Computers and Control Systems/Engine Control Module/Testing and Inspection - On vehicles with an automatic transmission, the Transmission Control Module (TCM) must also be adapted. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Throttle valve not damaged or dirty. - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C See display group 04, display field 3. NOTE: Only gold plated contacts can be used to repair the contacts in the connector for the throttle valve control module. - Connect VAG1551 (VAG1552) Scan Tool (ST). See: Computers and Control Systems/Testing and Inspection - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -6- and -2- to input display group number 62 (062) and press -Q- button to confirm input. - Check angle sensor -1- for for throttle drive (power accelerator actuation) -G187- on idle speed stop in display field 1. - Check angle sensor -2- for for throttle drive (power accelerator actuation) -G188- on idle speed stop in display field 2. - Depress accelerator slowly until Wide Open Throttle (WOT) position and observe angles displayed in display fields 1 and 2. The percentage displayed in display field 1 must rise continuously and evenly. The full tolerance range (3-93%) is not always displayed. The percentage displayed in display field 2 must fall continuously and evenly. The full tolerance range (97-3%) is not always displayed. Page 2057 Valve Spring: Tools and Equipment Valve Spring Compressor - AST Tool # VW 541-1 A Valve Spring Compressor AST tool# VW 541-1 A Valve Spring Compressor. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3514 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2642 If no malfunctions are found in wires: - Check voltage supply of Engine Control Module (ECM). See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Control Module (ECM) Voltage Supply, Checking - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes With Manufacturer's Scan Tool Throttle Valve Control Module, Checking Components of the throttle valve control module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1 - for for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for for throttle drive (power accelerator actuation) -G188NOTE: - If the throttle valve control module is replaced, the new control module must be matched to the Engine Control Module (ECM). Refer to "Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation", See: Engine Control Module/Testing and Inspection - On vehicles with an automatic transmission, the Transmission Control Module (TCM) must also be adapted. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Throttle valve not damaged or dirty. - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3 NOTE: Only gold plated contacts can be used to repair the contacts in the connector for the throttle valve control module. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-1-6- and -2- to input display group number 62 (062) and press -Q- button to confirm input. - Check angle sensor -1- for for throttle drive (power accelerator actuation) -G187- on idle speed stop in display field 1. - Check angle sensor -2- for for throttle drive (power accelerator actuation) -G188- on idle speed stop in display field 2. Page 2330 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5483 Brake Pedal Assy: Service and Repair Removing and Installing Removing ^ Remove trim below instrument panel. ^ Remove screws -1-. ^ Remove cover -A-. ^ Remove connecting plate between clutch and brake pedals on vehicles with a manual transmission. ^ Remove brake light switch -1-. ^ Disconnect accelerator cable. ^ On vehicles with accelerator pedal position sensor, release connector below instrument panel. ^ Disconnect brake pedal from brake booster. ^ Remove hex nuts, item -2-. ^ Remove pedal cluster. ^ Remove brake pedal. Installing Install in reverse order of removal. ^ Adjust brake light switch Page 4927 Special tools, testers and auxiliary items required ^ Thrust pad VW447 1 ^ Pressing appliance VW459/2 ^ Thrust pad 40 - 105 ^ Box wrench SW 32 3252 A ^ Assembly tool 3253 ^ Collar for wheel bearing inner race 3423 Page 3443 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 221 Vehicle Information Sunroof and Central Control Module -J393- Diagnosis Technical Background Sunroof may malfunction or fail to operate due to low battery voltage, battery being discharged, battery being disconnected, power to sunroof being interrupted while in operation, or a faulty central control module. Production Solution No production change required. Service Symptoms Sunroof inoperative. Sunroof will not close (stuck open or stuck open in the tilt position). Sunroof operates erratically (opens when sunroof switch is turned to the tilt position or tilts when sunroof switch is turned to the open position). Warranty When procedure applies to vehicles within any warranty, use applicable claim coding per Warranty Policy and Procedures Manual and ElsaWeb. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 5111 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 2937 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3492 Engine Control Module: Tools and Equipment Wire Terminal Extractor AST tool# H 4673-9 Page 2722 Wire Terminal Extractor used for ECU and ABS harnesses on 1998-2005 Jetta and Passat. The blade of the H 4673-9 has a width of 1mm. - Made in Germany - Easy to Use Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2335 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3019 Spark Plug: Application and ID Engine Code AFP Spark plugs 1) VW Audi 101 000 035 AH Manufacturers Code BKR 5 EKUP Electrode gap max. 0.7 Tightening torque 25 Nm (18 ft lb) 1) Use tool T10029 for disconnecting and connecting the spark plug connector. Remove and install the spark plugs using tool 3122B With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 1338 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Page 3470 Engine Control Module: Locations Engine Control Module Engine Control Module location The control module is located in plenum chamber. With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 474 Part 2 Page 2115 Wu-Ze Worldwide List of Engine Oils Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 3401 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2408 Part 1 Page 5916 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Page 1883 Page 2121 Engine Oil: Service and Repair For further information regarding this component please refer to Lubrication Systems; Service and Repair. Page 274 Page 5560 3 Cap ^ Install in mounting bushing 4 Guide pin, 28 Nm (21 ft. lbs.) ^ Removing and installing 5 Mounting bushing ^ Install in brake caliper housing 6 Brake caliper housing 7 Protective seal 8 Piston ^ Before installing apply a thin coat of assembly lubricant, Part No. G 052 150 A2, to piston 9 Piston seal Front brake caliper piston, removing and installing Special tools and equipment required ^ 3409 Wedge ^ Piston resetting tool Removing ^ Force piston out of brake caliper housing using compressed air. Note: Place a piece of wood in the recess to prevent damaging the piston. Page 4661 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1395 Impact Sensor: Service and Repair Crash Sensor For Driver Side/Passenger Side Curtain Protection, Removing and Installing Crash Sensor For Driver Side/passenger Side Curtain Protection, Removing And Installing NOTE: - Removal and installation is described for left side of vehicle. same instructions apply for removal and installation for right-hand side. - Observe notes regarding coding in radio operators manual before disconnecting battery. - After connecting battery, vehicle options (radio, clock, electric window regulator) must be checked according to repair manual and/or user manual. Removing - Switch ignition off. - Disconnect battery Ground (GND) strap. - Remove driver/passenger seat. CAUTION: Observe safety precautions for working on airbags. - Remove floor carpet - 4 - and insulation mat in sensor area. CAUTION: Electrostatic charges may result in involuntary deployment of airbag. Therefore, mechanic must be electrostatically discharged before disconnecting ignition- and Ground (GND) wires. This is done e.g. by briefly grasping chassis or door striker. - Disconnect harness connector - 2 - and unscrew two bolts - 3 - (6 Nm). Page 1176 Wire resistance: max: 1.5 Ohm Continuation for all vehicles - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4841 - T10038 Tensioning strap - V.A.G 1331 Torque wrench or equivalent Removing valve body Remove multi-function switch -F125-. - Raise vehicle. - Remove noise insulation tray. - Place drip tray under transmission. - Remove drain plug -arrow-. - Drain ATF. - Remove Ground strap -1- from retainer on transmission. Page 889 A/C Pressure Sensor/Switch - Cooling Fan: Locations High Pressure Sensor G65 G65 High Pressure Sensor in engine compartment, right rear, in refrigerant line Page 3172 If the specified values are not attained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector terminals: Terminal 1 + socket 92 - Terminal -2- + socket 83 - Terminal -3- + socket 117 - Terminal -4- + socket 84 - Terminal -5- + socket 118 - Terminal -6- + socket 91 - Wiring resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive or Ground. Specified value: infinity ohms If no malfunction is found in the wiring: - Check Engine Control Module (ECM) voltage supply. Refer to "Engine Control Module (ECM) Voltage Supply, Checking", See: Engine Control Module/Testing and Inspection Page 1104 ^ If there is no ESP or ASR switch and only a blank cover -2-, apply adhesive tape to instrument panel under cover, use a flat screw driver -A- to remove cover. ^ Insert assembly tool T10034 into opening, release clip holding emergency light switch -3- and pull it out of instrument panel. ^ Disconnect connector from emergency light switch. ^ On new emergency light switch (1J0 953 235 J 01C) reconnect connector and install switch into instrument panel. ^ Reinstall blank cover and remove adhesive tape. ^ Check turn signal and emergency light switch for correct operation. ^ Check all turn signal and emergency light switch bulbs for illumination and replace as required. ^ Destroy and properly dispose of removed part(s). Section B - Emergency Light Switch Replacement on Vehicles with ESP or ASR Page 4882 Note: If the assembly bolt (item 12) is not available, an M 8 x 35 bolt can be used. Page 2499 Radiator Cooling Fan Control Module: Connector Views Coolant Fan Control (FC) Module, Double Speed, W/After-run Coolant (Model Year 1999) Page 5468 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Rear Axle 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant G 000 650 2 Hex socket head bolt, 8 Nm (70 inch lbs.) 3 Stub axle 4 Splash shield 5 Wheel hub with wheel bearing and speed sensor rotor ^ Replace each time after disassembly ^ Only replace complete 6 Self locking 12 point nut, 175 Nm (129 ft. lbs.) ^ Replace each time after removing 7 Cap ^ Pressing off and driving in 8 Brake disc 9 Screw 10 Hex bolt, 60 Nm (44 ft. lbs.) ^ With dished spring 11 Axle beam Wheel speed sensor on rear axle, removing and installing Removing ^ Raise vehicle. Page 1371 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Page 478 Body Control Module: Connector Views Central Control Module For Comfort System; Power Sunroof Control Module Control Modules - Connector Pin-out Page 5628 B Primary piston circuit Page 5626 Hydraulic Control Assembly - Antilock Brakes: Locations Note: Complete brake master cylinders and brake boosters can be replaced separately. 1 Brake Booster ^ For gasoline engines vacuum is taken from the intake manifold ^ Diesel engines have a vacuum pump to create the required vacuum ^ Functional check: With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in the unit) - Hold brake pedal with average foot pressure in brake position and start engine. If brake booster is functioning properly, brake pedal should give noticeably underfoot. ^ If pedal does not give, replace brake booster ^ Check valve (in vacuum hose) Functional check ^ Separating from brake pedal. 2 Cap 3 Brake fluid reservoir 4 Plug ^ Coat with brake fluid and press into reservoir 5 Retaining pin ^ Insert through brake master cylinder 6 Brake master cylinder ^ Cannot be repaired. If faulty, replace as complete unit 7 Hex nut, self locking 20 Nm (15 ft. lbs.) 8 Bolt, 8 Nm (70 inch lbs.) 9 Cap nut, 20 Nm (15 ft. lbs.) 10 ABS/EDL hydraulic unit 11 ABS control module Page 4098 and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Locations A/C Pressure Switch F129 F129 A/C Pressure Switch - engine compartment, right rear Not Available For Manufacturer's Scan Tool Variable Valve Timing Actuator: Testing and Inspection Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. Page 5239 Test Step 1 - 2 Locations Engine Oil Filler / Breather Cap: Locations Underhood View: Always heed all WARNINGS: See: Maintenance/Service Precautions Always exercise extreme caution when working under the engine hood. Gasoline Engine 174 Hp (2.8L) 1 - Windshield washer container 2 - Coolant expansion tank 3 - Engine oil dipstick 4 - Engine oil filler cap 5 - Brake fluid reservoir 6 - Vehicle battery (protected by a cover} Page 4746 - Kukko 22/2 support -A-. - Kukko extractor 21/3 (18.5-23.5mm) -BTurbine shaft bushing, removing With transmission removed, remove bushing from turbine shaft as follows: - Remove torque converter. - Install extractor 21/3 to support 22/2. - Insert extractor into turbine shaft as shown. - Adjust size of extractor to size of bushing (do not over-adjust extractor). - Remove bushing from transmission. - Replace torque converter oil seal on ATF pump (see ElsaWeb, Repair Manual, Repair Group 32 "Torque converter oil seal, removing and installing". - Install new torque converter. Warranty Required Parts and Tools Page 2378 ^ Remove wires from sensor connector and clean connector housing. ^ Cut brown/white wire from sensor harness and tape back into harness (see above - Unused wiring, taping back to harness). Using light yellow splice connectors Part No: 111971941A: ^ Adding wire as necessary to reach sensor, splice appropriate wire with terminal on brown/white wire of overlay harness. ^ Insert terminal from overlay harness into appropriate cavity of sensor connector. ^ Install new wire with terminal on remaining factory harness wire using appropriate connectors/wires from the VAS 1978 kit. ^ Insert into appropriate cavity of sensor connector. ^ Reinstall connector on sensor. Fuel fuel gauge sensor overlay harness, preparing for Diesel vehicles Tip: Vehicles with TDI engines do not use an in-tank fuel pump. For vehicles with TDI engine, perform the following prior to installing harness: ^ Remove wire terminals from fuel pump harness connector -A- and discard connector. ^ Cut terminals from two large wires, fold and tape wires (Blue/red and brown at both ends of harness) back into harness using vinyl tape (see above - Unused wiring, taping back to harness). ^ Insert two small wires from overlay harness into appropriate cavities of two wire fuel gauge sensor connector -B- (provided in kit). Fuel pump / fuel gauge sensor overlay harness, preparing factory harness ^ Disconnect fuel pump / fuel gauge sensor connector including cable guiding. ^ Loosen fuel pump / fuel gauge sensor wiring harness from its attachment point below the seat belt on passenger side "B" pillar. ^ Remove tape covering from wiring harness, starting where fuel pump harness joins the main harness (arrow) and working forward to a point approx. 5 cm (2 inches) in front of the attachment point (loosened earlier at "B" pillar). Page 3615 Learning prerequisites for part load: - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C If the specified value is obtained: - Change to display group 33 as follows: - VAG1551: Press button 3 - VAG1552: Press button up arrow Indicated on display: (1-2 = display fields) Read Measuring Value Block 33 -> 12 - Observe Oxygen Sensor (O2S) control in display field 1. If the specified value is obtained: Display Group 033 If the specified value is obtained: CAN-Bus, Checking Engine Control Module: Testing and Inspection CAN-Bus, Checking With Manufacturer's Scan Tool Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. Page 3303 Use this function to observe status of communication between control modules via the Powertrain CAN Bus.. The measuring value block is divided into 2 display groups, each containing 4 display fields. - Connect VAG 1551, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 17 "instrument cluster". - Press -Q- button to confirm input. - Press -> button until "Select function"is displayed. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display: Rapid data transfer Q 08 - Read Measuring Value Block - Press -Q- button to confirm input. Indicated on display: Read Measuring Value Block HELP Enter display group number XXX - Using the Scan Tool (ST) button pad, enter the required display group number (following example shows display group 001). - Press -Q- button to confirm input. Indicated on display: (1...4 = Display fields) Read Measuring Value Block 1 -> 1234 Page 5939 ^ Take a sharp awl and put a hole into emblem on the point shown. Tip: Apply gentle pressure on the awl while using a circular motion to pierce through emblem. Once through surface: ^ Tilt awl at a 45 degrees angle. ^ Pry back till emblem comes off. EMBLEM INSTALLATION Attach new emblem Part No: 3B0 837 891 09Z, with a small drop of 3M quick fix adhesive Part No: 08155. Tip: Fold over a piece of tape, sticky side out and place on logo side of emblem. This helps to line up emblem correctly on the key. Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front Suspension Front Suspension Strut, Servicing Special tools ^ T10001 Special tools for struts/shock absorbers ^ VAG 1752/1 Suspension strut clamp ^ 3186 Socket wrench 21 mm AF ^ VAG 1752/4 Spring retainer ^ 3424 Spreader tool Page 3068 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Relay Locations Compiled From Every Wiring Section 1998-2004 Fuel Pump Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1677 Coolant: Fluid Type Specifications Coolant (Antifreeze), Mixing Precautions Models: All New antifreeze, Part No: G 012 A8F A4: Color = Purple Replaces Part No: ZVW 237 G12 (Pink) Can be mixed with ZVW 237 G12 (Pink) DO NOT mix with ZVW 237 105 (green) or any aftermarket antifreeze DOES NOT replace Part No: ZVW 237 105 (green) Antifreeze, Part No: ZVW 237 G12: Color = Pink Can be mixed with G 012 A8F A4 (purple) DO NOT mix with ZVW 237 105 (green) or any aftermarket antifreeze DOES NOT replace Part No: ZVW 237 105 (green) Regular antifreeze, Part No: ZVW 237 105: Color = Green DOES NOT replace and cannot be mixed with Part No: G 012 A8F A4 (purple) DOES NOT replace and cannot be mixed with Part No: ZVW 237 G12 (Pink) Follow coolant mixing instructions Cooling system - Service and Repair - Procedures - Draining and Filling, for the Model you are working on. Engine Coolant Coolant Type Type ..................................................................................................................................................... ................................................................... G12 (red) The coolant additives G11 (color: green) and G12 must never be mixed together. Mixing can cause serious engine damage. Page 4215 Part 1 Page 2892 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4079 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Service and Repair Cabin Air Filter: Service and Repair Dust and pollen filter, removing and installing 1 - Air deflector 2 - Frame 3 - Dust and pollen filter element 4 - Plastic nut, 2.5 Nm (22 in. lb) 5 - Filter housing Removing With plenum cover removed: - Depress tabs at front edge of frame -2-. - Lift and pull out filter element with frame to front. Installing - Assemble filter element to frame - Insert so that pins fit into into filter housing -5-. - Clip frame into place. Page 4678 - Slide 0.8 mm feeler gauge between locking lever and selector lever roller. - Pull locking cable outer sleeve lightly forward in direction of travel -arrow 1- and push red clip downward until it engages -arrow 2-. - Push sliding sleeve over clip. - Check operation of ignition key withdrawal lock. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Ignition System/Service Precautions/Technician Safety Information Page 1962 Note: Use only fork wrench SW 24 to place against camshaft -arrow-. The camshaft ruler 3268 must not be inserted when tightening or loosening the sprockets. - Remove camshaft sprockets. Camshaft, cylinder row 1, 3 and 5 - Remove bearing covers 1 and 7 first. - Loosen bearing covers 3 and 5 in an alternating and crosswise pattern. Camshaft, cylinder row 2, 4 and 6 - Remove bearing cover 4 first. - Loosen bearing covers 2 and 6 in an alternating and crosswise pattern. Installing - Oil camshaft running faces. Notes: During camshaft installation, the camshaft sprocket recesses -arrows must point upward. - Make sure that during bearing cover installation the markings on the covers are visible from the exhaust side of the cylinder head, and that the arrows point in the direction of the oscillation damper side. Camshaft, cylinder row 1, 3 and 5 - Tighten bearing covers 3 and 5 in an alternating and crosswise pattern and then finish tightening to 20 Nm. - Install bearing covers 1 and 7 and also tighten to 20 Nm. Camshaft, cylinder row 2, 4 and 6 Page 6511 - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake drum. - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Page 4207 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 3379 - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 6,4...47,5 Ohm (at room temperature) If specified value is not obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-: Vehicles with engine code AFP, item 9. - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module: Service and Repair Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation Adaptation teaches the Engine Control Module (ECM) (with ignition switched on and engine not running) the throttle valve control module stop positions and a comparison graph between throttle valve potentiometer and throttle position sensor. Adapting sequence must be performed if: - The voltage supply is interrupted - The throttle valve control module is removed and installed - The throttle valve control module is replaced - If when installing another engine another throttle valve control module is installed Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - No DTCs stored in DTC memory. - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - Throttle valve must be at idle speed position Work sequence Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select data function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -6- and -0- to input display group number 60 (060) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 60 -> 1234 After pressing the -Q- button, the throttle valve position sensor is switched so that it is not supplied with voltage at the start of the test. In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in the throttle valve control module. The values that both angle sensors provide in the emergency running position are stored by the Engine Control Module (ECM). Thereafter, the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle valve to the previously learned emergency running position within a predetermined period (spring test). Then the throttle valve is closed by the throttle valve positioner, and the values, which are supplied by the angle sensors in the throttle valve control module, are stored by the Engine Control Module (ECM). If the Engine Control Module (ECM) switches the throttle valve position sensor so that it is without voltage during normal operation, it is indicated by an increased and varying idle. The engine reacts slowly to accelerator changes. - Check specified values (display fields 1-4): Locations Engine Oil Dip Stick - Dip Stick Tube: Locations Underhood View: Always heed all WARNINGS: See: Maintenance/Service Precautions Always exercise extreme caution when working under the engine hood. Gasoline Engine 174 Hp (2.8L) 1 - Windshield washer container 2 - Coolant expansion tank 3 - Engine oil dipstick 4 - Engine oil filler cap 5 - Brake fluid reservoir 6 - Vehicle battery (protected by a cover} Page 3812 If specified values are not obtained: - Replacing Leak detection pump (LDP) -V144-. Vehicles with engine code AFP, item 8, - Vehicles with engine code BDF, item 7. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified values are obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 1 + socket 80 Terminal 2 + socket 25 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms - Check wire between 3-pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2531 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Service and Repair Traction Control Switch: Service and Repair Removing and installing is the same for all switches and only the emergency flasher switch -E3- is described here. The switch consists of a switch housing and a switch trim with the relevant symbol. The switch trim is clipped onto the switch housing. If the switch trim is released instead of the switch during the removal sequence, the switch trim must be reclipped onto the switch housing after completing the work. The switch must be pulled, together with the connected wiring, out of the instrument panel to separate the connection. It may be necessary to remove the harness connector of the switch on the left of the relevant switch, so that the wiring to the switch can be pulled out sufficiently. Removing switch - Protect instrument panel around the cover with adhesive tape if necessary. - Release switch carefully from instrument panel using blade of knife or screwdriver and remove. - Release harness connectors and remove. Installing switch - Connect harness connector. - Push switch into mounting and engage. - Clip switch trim onto switch housing if necessary. Page 100 - Antenna cables - New Beetle with Satellite radio (convertible) - Antenna cables - W8 Passat Load Reduction Relay Power Distribution Relay: Locations Load Reduction Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Powertrain Management/Ignition System/Service Precautions/Technician Safety Information Recall 04V096000: Brake Light Switch Malfunction Brake Light Switch: All Technical Service Bulletins Recall 04V096000: Brake Light Switch Malfunction DEFECT: The brake light switch on these vehicles may malfunction. If this happens, the brake lights could become inoperative, or come on and stay on, even though the vehicle is parked. REMEDY: Dealers will replace these switches. The manufacturer has reported that owner notification is expected to begin during April 2004. Owners may contact Volkswagen at 1-800-822-8987. Page 2471 Auxiliary radiator 1. 10 Nm 2. Retaining frame for auxiliary radiator 3. Spacer sleeve 4. Rubber disk 5. Lower bolt, 10 Nm 6. Air scoop 7. Auxiliary radiator for vehicles in hot climates 8. 5Nm 9. To Y-branch of upper coolant hose 10. To Y-branch of lower coolant hose 11. Bracket for auxiliary radiator Cooling system components, engine side Page 3792 Catalytic Converter: Testing and Inspection With Generic Scan Tool Three Way Catalytic Converter (TWC), Checking Function test - Select the measuring value "Test-ID 01: Catalytic converter" and check whether the specified values are being reached, Diagnostic mode 6: Check test results of components that are not continuously monitored. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 6: Check Test of Parts Not Constantly Monitored - End diagnosis and switch ignition off. If the specified values are exceeded: - Replace the front exhaust pipe with catalytic converter: Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 14. Continuation for all vehicles - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2785 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Locations Fuel Gauge Sender: Locations G - Sender for fuel gauge (fuel level sensor) Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Locations Brake Fluid Pressure Sensor/Switch: Locations G201 - Brake Pressure Sensor 1 (vehicles with ESP) Main Radiator Radiator: Service and Repair Main Radiator Radiator, removing and installing Special tools and equipment VAG 1306 Drip tray for VAG 1 202A VAG 1331 Torque wrench (5-50 Nm) or equivalent VAG 1921 Hose clip pliers Hydrometer Main radiator Auxiliary radiator, refer to See: Auxiliary Radiator Removing - Drain coolant, refer to Coolant - Service and Repair - Procedures See: Coolant/Service and Repair - Remove front bumper, refer to Body and Frame - Bumper - Service and Repair Procedures - Pull quick-coupler off radiator. - Disconnect connectors from thermo switch and coolant fans. - Place lock carrier into service position, refer to Body and Frame - Service and Repair - Procedures See: Body and Frame/Lock Carrier/Service and Repair/Procedures - Remove radiator retaining screws and remove radiator and fan from below. Notes and assembly procedures for vehicles with air conditioning CAUTION! Do not open the A/C refrigerant circuit. Page 5226 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Page 1753 Li-Pe Page 5121 Transmission Position Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 4618 Special tools and equipment VW771 Multipurpose tool - VW771/37 Puller hooks - V.A.G 1 306 Drip tray - V.A.G 1331 Torque wrench - V.A.G 1 332 Torque wrench - T10088 Thrust piece Removing right-hand flange shaft seal Page 5797 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Page 3604 - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -0button to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -4- and -1- to input display group number 41(041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 4. Page 904 High Pressure Sensor / Switch: Description and Operation High Pressure Sensor G65 High pressure sensor -G65Where applicable, high pressure sensor - G65- -B-, transmits a square wave signal to Coolant Fan Control (FC) Module -J293- at a rate which varies according to the refrigerant system pressure. -J293 reacts to the pulse rate of the signal from -G65 as follows: - If the refrigerant system pressure rises, -J293- switches the radiator fan(s) to the second speed. - Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), -J293- switches A/C clutch -N25- off (-N25- controlled by J293-). - On Climatronic equipped models it informs the A/C control head -E87- that the pressure in the refrigerant system is OK and that A/C clutch -N25- can be switched on (-N25- controlled by -J293-). On applicable engines, the signal generated by -G65- is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance. NOTE: - The presence of -G65- is engine dependant. Where -G65- is not used, A/C pressure switch -F129- is used instead. - Where -G65- is used, it's wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of -G65- and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Specifications Crankshaft Main Bearing: Specifications Crankshaft Main bearing measurements 59.958 - 59.978 mm Crankshaft Bearing cover Bolts 30 Nm plus 1/2 turn Page 62 If reception does not return: ^ Problem is located further forward in the system. For problems forward of the antenna system: - Continue with Section 3a. For problems at antenna system: Skip to Section 3b. For problems at antenna systems: Tip: All checks should be done outdoors away from buildings. Section 3a - Problems forward of antenna system - First verify connection at Radio (check for bent or crushed connections and proper fit). If all connections appear ok: - Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception). If reception returns: ^ Problem is located between radio and antenna. - Check connections near center console: If connections are OK: - Check resistance of cable from end to end. ^ If More than .4 ohms: - Replace cable. If reception does not return; - Replace radio unit. Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8) If concern is only AM poor / no reception; Locate AM antenna amplifier. ^ Touareg: located above left side window. ^ Passat W8: Sedan above rear window. ^ Passat Wagon: located on left rear window. - Check for proper connections at amplifier both from diversity box and to glass. If connection issue is at glass or on glass: - Glass must be replaced. If connection problem to amplifier: - Repair connection (replace cable or amplifier). Page 1349 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Locations Acceleration/Deceleration Sensor: Locations G419 - ESP-Sensor Unit (vehicles with ESP) Page 5709 Page 2687 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 1208 - Perform resistance measurement on Intake Air Temperature (IAT) sensor -G42-, terminals -1(signal) and 3 (Ground (GND)). Scale -A- shows resistance values for temperature range 0-50 °C and scale -B- shows the values for temperature range 50-100 °C. Examples: - 30 °C is in range -A- and corresponds to a resistance of 1.5-2.0 Kohms - 80 °C is in range -B- and corresponds to a resistance of 275-375 Kohms If the specified value is not obtained: - Replace Mass Air Flow (MAF) sensor -G70-, item -24-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 5857 - Commercially available hydrometer - Battery filling bottle VAG5075 A correct electrolyte level in the battery is an important factor in ensuring a long battery service life. An insufficient electrolyte level allows the battery plates to dry which results in a loss of capacity (reduced output) of the battery. If the cell plates are not covered by electrolyte, the plates, the plate bridges and the cell connections will corrode. This corrosion ensures the battery function can no longer be guaranteed. The battery is unusable. If the electrolyte level is too high, damage will be caused outside the battery by the leaking battery acid (sulphuric acid/water mixture) e.g. components in engine compartment. A visual check of the battery acid level is all that is required on batteries with a recognizable minimum and maximum marking. - Switch ignition off. - Check acid level visually. The acid level is OK when the fluid level is between the minimum and maximum marking. If no minimum and maximum markings are visible on the battery housing, the sealing plugs must be removed. It is then possible to view the electrolyte level by viewing the inside of the battery cells. - Check acid level visually. The electrolyte level is OK when the fluid level is the same height as the visible plastic peg. The plastic peg equates to the max. marking for the electrolyte level. If the electrolyte level is not OK, correct level as follows: - Remove battery sealing plug. - Use hydrometer to extract excessive electrolyte until fluid level is same as inner plastic peg level marking if the electrolyte level is too high. - If electrolyte level is too low, fill up to max. marking with distilled water using battery filling bottle VAS5045. NOTES: Adjustments Steering Gear: Adjustments Steering gear, adjusting NOTE: Two mechanics required. Adjust with engine turned off. - Raise vehicle on hoist and with wheels straight-ahead. - Turning steering wheel back and forth (30 from center) a knocking noise will be heard if play is excessive. - Second mechanic carefully turns adjustment screw in until knocking noise can no longer be heard from inside vehicle. - Perform road test to ensure steering returns to center without sticking. - Secure lock nut with a punch mark (arrow). Page 4168 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Page 3052 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 3622 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -3- and -4(harness connector to Engine Control Module (ECM)). - Start engine and run at idle. - Measure voltage supply and observe display group 41, display field 2. Display: Htg.bC.ON Specified value: 11.0-14.5 V Display: Htg. bC.ON/Htg.bC.OFF (alternating) Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 3285 Indicated on display: Rapid data transfer HELP Select function XX - After the HELP button is pressed, a list of the possible functions is printed out. List of available functions Page 6395 VAG 1383A Engine/transmission jack ^ VAG 1383A Engine/transmission jack Removing WARNING: Vehicle must be standing on its wheels when loosening or tightening 12 point axle nut. - Loosen 12-point axle nut. - Lift vehicle to relieve load on front axle and remove noise insulation. - Remove bolts (arrows). - Press axle shaft out. Position tool as shown. NOTE: ^ When pressing the drive axle out make sure that sufficient clearance is available. ^ Do not allow drive axle to hang by inner CV or triple-rotor joint to avoid damaging bearing surfaces. Tie drive axle to stabilizer bar or other suspension component if it is to remain attached to drive flange. ^ Do not flex inner CV or triple-rotorjoint more than 25 degrees from its original angle. - Pull wheel bearing housing with ball joint out from control arm. Page 2771 - Measure resistance between terminals 2+3 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Continuation for all vehicles If specified values are not obtained: - Replace Clutch Vacuum Vent Valve Switch -F36-. NOTE: Note installation position of clutch vacuum vent valve switch in the upper installation bore of mounting bracket. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified values are obtained: Vehicles with 2-pin clutch vacuum vent valve switch - Connect multimeter between terminal 1 and Ground (GND) for voltage measurement. - Switch ignition on. Specified value: at least 11.5 V - Switch ignition off. If specified value is not obtained: - Check wire between 2-pin connector terminal 1 and central electronics for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 1823 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) Switch - above clutch pedal - above clutch vacuum vent valve -F36- Page 5895 - Release socket drive -1- and pull off grip -2-. - Turn torque wrench grip -2-through 180 ° and reinsert socket drive. - Set wrench direction of turn on socket drive to anti-clockwise. - Set torque wrench tightening torque to 80 Nm. - Fit 6 mm socket onto generator drive shaft. - Counter-hold multi point key 3400 with 17 mm ring spanner and tighten freewheel disc to 80 Nm by turning generator drive shaft anti-clockwise with torque wrench. - Clip protective cap onto freewheel disc. Page 4566 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Page 3276 Diagrams/Electrical Diagrams/Master Diagram Index Diagram 74/6 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Page 2584 L4 Engine W/1 Exhaust Banks & 1 Catalysts Page 3878 30 - Connector - Black, 4-way 31 - 10 Nm Fig. 1 Fitting position of the fuel delivery module flange Markings on the sensor must agree with those on the fuel tank -arrows-. Return line -1- with blue or with blue markings at port labeled -R-. Black feed line -2- at port labeled -V-. NOTE: After the flange of the fuel delivery module is installed, check that the feed, return, and vent lines are still clipped onto the fuel tank. Fig. 2 Switch valve, check Lever in rest position: closed Lever pressed in direction of arrow: open NOTE: Remove the fuel tank cover before installing the switch valve. Fig. 3 Checking the pressure valve Page 5378 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 5232 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Battery Handling Instructions Battery: Service and Repair Battery Handling Instructions NOTES: - Battery terminals must no longer be greased. - Battery terminal clamps must only be connected by hand without force in order to prevent damage to the battery housing. - The tightening torque for the battery terminal clamp is 6 Nm (53 in. lb). - The tightening torque for the additional terminals on the battery terminal clamp is 6 Nm (53 in. lb). - When the battery has been reconnected, check operation of electrical equipment (radio, clock and convenience electrics etc.) according to the Repair Manual or the Owner's Manual. - For OBD II vehicles, the readiness code for the Engine Control Module (ECM) must be re-generated after the battery has been disconnected. Warnings and safety measures for handling lead-acid batteries 1 - Read and follow all instructions regarding the battery that are contained in this Repair Manual and in the Owner's Manual. 2 - Danger from acid burns: - When working with electrolyte always wear eye protection and rubber gloves. - Never tip a battery on edge. Electrolyte can spill from the ventilation openings. 3 - Keep open flames and sparks away and DO NOT smoke near batteries! - Avoid sparks when working with cables and electrical units. - Avoid short circuits. 4 - Wear eye protection. 5 - Keep children away from acid and batteries. 6 - Disposal: - Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal. 7 - Never dispose of old batteries in household waste! 8 - Danger of explosion: - A highly explosive gas is produced when charging batteries. Page 185 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2102 Li-Pe Page 5331 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 5047 Shifter M/T: Service and Repair Gear Lever and Gear Lever Housing Servicing 5 Speed Manual 02J Gear lever and gear lever housing, servicing Note: Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2. 1. Circlip - Removing and installing = Fig. 1 2. Bushing 3. Spring 4. Bushing 5. Torx screw, 5 Nm 6. Cover plate 7. Damper 8. Bearing shell 9. Gear shift guide 10. Damping washer 11. Gasket - Between selector housing and floor - Self adhesive Page 1874 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL), Significance Malfunction Indicator Lamp (MIL), Significance If malfunctions are recognized by the Motronic Engine Control Module (ECM) -J220-, the Malfunction Indicator Lamp (MIL) will be switched on. In vehicles from m.y. 2000, this is done by a signal sent by the ECM to the instrument cluster Location of Malfunction Indicator Lamp (MIL) NOTE: The MIL can switch on in the "flashing" or "permanently on" mode. DTC memory must be checked in every case. - Flashing: There is a malfunction which can cause damage to the Three Way Catalytic Converter (TWC) if driven in this condition. In this case, the vehicle must not be driven using full performance! - Permanently on: There is a malfunction which will increase exhaust emissions. Check DTC memory of the Motronic Engine Control Module (ECM) and/or automatic Transmission Control Module (TCM). - If the MIL does not light up even though there is an engine running problem, or a customer has complained, DTC memory must be checked, because malfunctions which do not switch the MIL on immediately can also be stored. Page 6363 If the displayed values in all display zones are OK: - Press -> button. NOTE: Check DTC Memory after completing the function "Read Measuring Value Block". Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Service and Repair Power Steering Fluid Reservoir: Service and Repair For further information regarding this component or the system it is a part of please refer to Power Steering Pump. Page 792 ^ Secure wheel speed sensor wire (arrows). Note: Do not twist wires in the wheel well. ^ Cut 2-pin connector at new speed sensor wire (if installed) using stripping pliers from repair kit. ^ Strip 15 mm (5/8 inch) insulation off wire end and fold over stripped wire. ^ Connect wheel speed sensor wire using correct connector from wiring repair kit VAS 1978. Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Maintenance Interval Indicator, Resetting Reset the service interval indicators in vehicles with service dependent on kilometers traveled or time You can reset the service interval indicator in two different ways: through the odometer adjustment key on the instrument panel, or - with the Diagnosis, Measurement and Information System VAS 5051A /52 Resetting service interval indicator, through 2007, on Instrument Panel Note: The service interval indicator must be reset at every inspection service! Reset the indicator as explained: - Turn the ignition off. - Press and hold button -1- beside the speedometer. - Turn the ignition on. In the indication -1-* or -2-** on the instrument panel (depending on the vehicle equipment) -1- the warning "OIL" or "INSP" is displayed on the reading unit -2- or a workshop symbol "is displayed on the indication unit ". Page 741 - Apply adhesive tape to instrument panel in area of switch. - Carefully release switch -2- (or switch -3- ) using a knife tip or a flat screwdriver -1- and remove. - Disengage and disconnect electrical harness connectors if necessary Installing - Connect and engage electrical harness connectors. - Insert switch -2- (or switch -3-) into vent and engage. Page 3909 - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If there is no malfunction in wire connection: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4423 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Page 6396 - Swing wheel with suspension strut out and support. - Install ball joint puller, as shown, and press out ball joint. WARNING: ^ Place engine/transmission jack VAG 1383A, or similar, underneath to ensure safety. ^ For safety reasons and to protect ball joint threads, leave nut threaded on a few turns. Installing - Install new self-locking nut, and counter-hold with T40 Torx hi: bit. 1. Torx bit T40 2. Box wrench insert or slotted ring wrench insert 3. VAG 1331 Install ball joint in wheel bearing housing. - Secure ball joint to control arm (bolts on old marks). Use new bolts! Page 4179 Test Step 3 - 6 Page 1755 Ca-Va Page 3292 - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 824 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5372 Volkswagen Canada, Inc. Recall - ABS Control Unit Replacement Technical Service Bulletin # RECALLWJ Date: 020301 Recall - ABS Control Unit Replacement Recall Circular Code: WJ Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit Dear Volkswagen Dealer: This is to inform you of the initiation of a voluntary safety recall involving some 2001 and 2002 model year Volkswagen Golf, Jetta, GTI and New Beetle vehicles. Problem Description Volkswagen has found that an electronic chip in the control unit could experience an electrical short causing the connector wire insulation to become scorched. Remedial Action Check and replace, where required, ABS control unit. Vehicle Identification Number Ranges The vehicles affected by this recall action are within the following vehicle identification number ranges: Please note that the above VINs represent the lowest and highest serial numbers of affected vehicles. Use of the OTIS campaign inquiry system will allow you to determine whether or not a particular vehicle, within the above VIN ranges, requires the corrective work. Note: Volkswagen will not reimburse under recall any duplicate recall repair work or a repair outside the VIN ranges. Owner Notification Mailing Volkswagen of America, Inc. will mail first class notification letters to all known owners of affected vehicles on or about March 14, 2002. A copy of the owner letter is enclosed for your information. Vehicle Allocation Under separate cover and prior to owner notification, we will provide you a computer printout list containing VINs including owner names and addresses of vehicles located within your dealership's area of responsibility. Note: The above listing will include names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts Information Diagrams Combination Switch: Diagrams Switch for windshield wiper and washer system and multi-function indicator A - Harness connector, 6-pin 1 - MFI call-up button - right 2 - MFI call-up button - left 3 - MFI call-up button - terminal 31 4 - MFI safe switch - Reset 5 - Windshield wiper intermittent circuit regulator - to automatic intermittent wash/wipe relay 6 - Windshield wiper intermittent circuit regulator - terminal 31 B - Harness connector, 8-pin 1 - Windshield wiper switch - terminal 53 2 - Windshield wiper switch - terminal 31 3 - Windshield wiper switch - terminal 53e 4 - Windshield wiper switch - terminal 53c 5 - Windshield wiper switch - rear window wiper 6 - Windshield wiper switch - terminal 53b 7 - Windshield wiper switch - intermittent operation 8 - Windshield wiper switch - terminal 53a Switch for turn signals, high and low beam, flasher and parking light C - Harness connector, 12 pin 1 - Switch for dimmer/flasher - terminal 30 2 - Switch for dimmer/flasher - terminal 30 3 - Turn signal switch - terminal L 4 - Vacant 5 - Turn signal switch - terminal 49a 6 - Horn plate - terminal 71 7 - Switch for dimmer/flasher - terminal 56 8 - Switch for dimmer/flasher - terminal 56b 9 - Vacant Page 663 Power Window Control Module: Locations J387 - Door Control Module, Passenger Side J386 - Door Control Module, Passenger Side - in right front door, on component carrier - integral with window motor -V148 - left-side control module -J386- shown Page 4469 Drain Plug: Locations 5 Speed 09A Transmission 5 Speed 09A Transmission Drain Plug............................................................................................................................................. ................................................................... 45 Nm Locations Parking Brake Warning Switch: Locations F9 - Parking brake warning light switch Page 6219 Alignment: Service and Repair Rear Wheel Camber, Adjusting Rear wheel camber, adjusting Camber cannot be adjusted. If vehicle checks outside of specification, check trim height and adjust if necessary. If specification cannot be obtained, check axle beam for damage and replace if necessary. Toe, Adjusting Rear wheel toe, adjusting If vehicle is out of specification, check trim height and balance if necessary Rear axle total toe is not adjustable Only by sliding brackets is it possible to balance individual toe values. If, after attempting above method, vehicle remains out of specification, check axle beam for damage and replace if necessary Loosen all bolts at bracket -1- Slide bracket -1- laterally. 2. Rear axle beam Tighten bolts 75 Nm (55 ft. lbs.). NOTE: Always use new bolts Page 3268 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4288 After selecting "Update - Programming" function, new program version as listed below will install: ^ 0009 for ECM Part No.: 021 906 018 A (1999) ^ 0009 for ECM Part No.: 021 906 018 B (1999) ^ 0007 for ECM Part No.: 021 906 018 K (2000) ^ 0007 for ECM Part No.: 021 906 018 M (2000) ^ 0003 for ECM Part No.: 021 906 018 Q (2000) ^ 0005 for ECM Part No.: 021 906 018 R (2001) ^ 0005 for ECM Part No.: 021 906 018 S (2001) ^ 0004 for ECM Part No.: 021 906 018 AA (2002) ^ 0004 for ECM Part No.: 021 906 018 T (2002) - By selecting the --> button, the programming procedure begins. Similar screen appears: The previous data in the ECM is erased and the new data is being transferred to the module from the flash CD. Note: Approx. flashing time is 24 minutes. Locations Glove Box Lamp Switch: Locations E26 - Glove compartment light switch Page 2847 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin connector according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 4-pin harness connector terminal -1- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms With Generic Scan Tool Oxygen Sensor And Oxygen Sensor Control Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 5061 - For support bracket 10. Cable locking mechanism - For gate selector cable to relay lever - Replace after removing from relay lever -item 14 - From 01.01 with holes - Not necessary to be replaced - Secured with securing clip - Removing and installing 11. Cable locking mechanism - For gear selector cable to gear selector lever - Replace after removing from transmission selector lever -item 16 - From 01.01 with holes - Not necessary to be replaced - Secured with securing clip - Removing and installing 12. Circlip 13. Bushing 14. Relay lever - Installation position 15. Shoe 16. Transmission - selector lever - With balance weight - Install so that master spline aligns with selector shaft - After installing adjust gear selector mechanism - Installation position 17. Hex nut, 20 Nm - Always replace Installation position of transmission selector lever/relay lever 1. Gear selector lever - With balance weight 2. Relay lever - Locates in guide rail of gear selector lever via shoe (arrow) Page 4666 Page 4061 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Page 4638 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 2805 - Perform resistance measurement on Intake Air Temperature (IAT) sensor -G42-, terminals -1(signal) and 3 (Ground (GND)). Scale -A- shows resistance values for temperature range 0-50 °C and scale -B- shows the values for temperature range 50-100 °C. Examples: - 30 °C is in range -A- and corresponds to a resistance of 1.5-2.0 Kohms - 80 °C is in range -B- and corresponds to a resistance of 275-375 Kohms If the specified value is not obtained: - Replace Mass Air Flow (MAF) sensor -G70-, item -24-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 1543 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4398 Electrical Check For Vehicles With Automatic Transmission 09A Multi-pin control module connector (68-pin connector) -J217- (sockets on V.A.G 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - Vacant 4 - Vacant 5 - K-lead of diagnosis 6 - Shift lock solenoid -N1107 - Intermediate shaft speed sensor -G265- (screening) 8 - Vacant 9 - Sensor for transmission RPM -G18210 - Sensor for transmission RPM -G18211 - Sensor for transmission RPM -G182- (screening) 12 - Vacant 13 - Vacant 14 - Vacant 15 - Data bus high input and output signals 16 - Data bus low input and output signals 17 - Brake pressure switch (only on vehicles with stationary decoupling) 18 - Multi-function transmission range switch -F12519 - Multi-function transmission range switch -F12520 - Vacant (for kickdown switch) 21 - 22 - Supply voltage (terminal 30) 23 - Vacant 24 - Ground (terminal 31) 25 - Solenoid valve 4 -N9126 - Solenoid valve 3 -N9027 - Vacant 28 - Intermediate shaft speed sensor -G26529 - Intermediate shaft speed sensor -G26530 - Vacant (for A/C kickdown) 31 - Vacant 32 - Vacant 33 - Transmission fluid temperature sensor -G93- (ATF) 34 - Transmission fluid temperature sensor -G93- (ATF) 35 - Vehicle speed sensor -G6836 - Vehicle speed sensor -G6837 - Vehicle speed sensor -G68- (screening) 38 - Vacant 39 - Vacant 40 - Multi-function transmission range switch -F12541 - Multi-function transmission range switch -F12542 - Vacant 43 - Vacant 44 - Vacant 45 - Supply voltage (terminal 15) Diagram Information and Instructions Shift Interlock Solenoid: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5643 Brake Master Cylinder: Locations Underhood View: Always heed all WARNINGS: See: Maintenance/Service Precautions Always exercise extreme caution when working under the engine hood. Gasoline Engine 174 Hp (2.8L) 1 - Windshield washer container 2 - Coolant expansion tank 3 - Engine oil dipstick 4 - Engine oil filler cap 5 - Brake fluid reservoir 6 - Vehicle battery (protected by a cover} Component Locations Fuse: Component Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 2700 Engine Control Module: Locations J220 - Motronic Engine Control Module (ECM) J220 - Motronic Engine Control Module (ECM) - in plenum, center - for gasoline engine with motronic MFI Page 4062 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Service Page 1482 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Component Locations Fuse Block: Component Locations Fuse Panel Location The fuse panel is located behind a cover on the driver side end panel of the instrument panel (dashboard). Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Initial Inspection and Diagnostic Overview Alarm Module: Initial Inspection and Diagnostic Overview General Information General Information Immobilizer functions supported by: - control electronics integrated with instrument cluster - a warning light for anti-theft immobilizer -K117- in instrument cluster (speedometer display) - an adapted engine control module - an induction coil on the ignition lock - Adapted ignition keys with electronic components (transponder and response reader memory) Malfunction Recognition and DTC Display Malfunction Recognition And Diagnostic Trouble Code (DTC) Display Via Warning Light For Anti-theft Immobilizer -K117An intact immobilizer system is indicated by the warning light for anti-theft immobilizer -K117lighting up and going out after approx. 3 seconds when the ignition is switched on. When the ignition is switched "on", the warning lamp flashes or lights up continuously to indicate a malfunction in the system when: - Adapting the ignition key has been carried out incorrectly - No transponder (response reader memory) is present in ignition key. - An unauthorized ignition key is used. - An unauthorized engine control module is detected. - A malfunction in the induction coil of anti- theft immobilizer -D2-. - A malfunction in the data wiring is present. The warning light for anti-theft immobilizer -K117- does not light up after switching on ignition: - The immobilizer control module has detected an authorized key. - The immobilizer control module has not detected an incorrect engine control module. - The immobilizer control module is currently "adapting keys" and after adapting the keys no malfunction has occurred. To troubleshoot, perform the On Board Diagnostic (OBD) program and retrieve the stored information with either the VAG 1551/1552 Scan Tool or VAS 5051 Vehicle Diagnostic, Testing and Information System. Page 6465 Wheel Bearing: Aftermarket Tools Rear Wheel Bearing Press AST tool# 3420 VW/Audi Rear Wheel Bearing Press. Applicable to Newer Golf, Jetta and New Beetle. - VW/Audi Rear Wheel Bearing Press - Applicable to Newer Golf, Jetta and New Beetle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Recall - ABS Control Unit Replacement Technical Service Bulletin # RECALLWJ Date: 020301 Recall - ABS Control Unit Replacement Recall Circular Code: WJ Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit Dear Volkswagen Dealer: This is to inform you of the initiation of a voluntary safety recall involving some 2001 and 2002 model year Volkswagen Golf, Jetta, GTI and New Beetle vehicles. Problem Description Volkswagen has found that an electronic chip in the control unit could experience an electrical short causing the connector wire insulation to become scorched. Remedial Action Check and replace, where required, ABS control unit. Vehicle Identification Number Ranges The vehicles affected by this recall action are within the following vehicle identification number ranges: Please note that the above VINs represent the lowest and highest serial numbers of affected vehicles. Use of the OTIS campaign inquiry system will allow you to determine whether or not a particular vehicle, within the above VIN ranges, requires the corrective work. Note: Volkswagen will not reimburse under recall any duplicate recall repair work or a repair outside the VIN ranges. Owner Notification Mailing Volkswagen of America, Inc. will mail first class notification letters to all known owners of affected vehicles on or about March 14, 2002. A copy of the owner letter is enclosed for your information. Vehicle Allocation Under separate cover and prior to owner notification, we will provide you a computer printout list containing VINs including owner names and addresses of vehicles located within your dealership's area of responsibility. Note: The above listing will include names and addresses obtained from state motor vehicle registrations. Under the law of most states, including regulations set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts Information Recall 06V183000: Brake Light Switch Defect Brake Light Switch: Recalls Recall 06V183000: Brake Light Switch Defect MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Jetta 1999-2002 Volkswagen/New Beetle 1998-2002 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 06V183000 MFG'S REPORT DATE: May 24, 2006 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 362000 SUMMARY: On certain passenger vehicles equipped with automatic transmissions and cruise controls, a brake light switch on these vehicles may malfunction if it was installed incorrectly during safety recalls 03V-265 OR 04V-096. CONSEQUENCE: The brake lights could become inoperative, or remain on. failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before December 8, 2006. Owners may contact VW at 1-800-822-8987. NOTES: VW recall No. N4. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 433 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Specifications Water Pump: Specifications Coolant Retaining screws 15 Nm Page 2638 - Use wiring diagram to check cables between test box and connector for any broken connections. Contact 1 + cavity 72 - Contact 2 + cavity 73 - Contact 3 + cavity 36 - Contact 4 + jack 35 - Contact 5 + jack 33 - Contact 6 + jack 34 - Line resistance: max. 1.5 Ohms - Also check cables for a short circuit to battery positive terminal or to ground. - Also check cables for short circuits between each other. If no problems can be found in the cables: - Replace throttle position sensor (G79), item -4-. Body - Sunroof Malfunctions or is Inoperative Central Control Module: All Technical Service Bulletins Body - Sunroof Malfunctions or is Inoperative 60 07 06 June 19, 2007 Page 1204 Display Group 4 Continuation of check when display = ambient temperature - Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module. - Note intake air temperature value in display field 4. - Spray sensor (arrow) with commercial chilling agent while observing temperature value. Temperature value must decrease. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation of check when display reads approx. -40.0 °C: Page 6308 ^ Ensure sealing surfaces are clean. - Install power steering gear on subframe. Threaded sleeve -1- must seat in hole on sub-frame. - Install return line. A gap of approx. 10 mm (0.39 in.) must exist between return line and power steering gear. 1. Return line 2. Nut, 22 Nm (16 ft. lbs.) 3. Steering gear Installation is performed in reverse sequence: Tightening torque: Power steering gear to sub-frame 20 Nm (15 ft. lbs.)+ 90° further Use new bolts! Sub-frame to body 100 Nm + (74 ft. lbs.) 90° further Use new bolts! Universal joint to steering gear 30 Nm (22 ft. lbs.) Use new bolts! Banjo bolt to steering 40 Nm (30 ft. gear M14 x 1.5 lb.) Banjo bolt to steering gear M 16x 1.5 45 Nm (33 ft. lbs.) Pendulum support to transmission 40 Nm (30 ft. lbs.) Tie rod to steering arm 45 Nm (33 ft. lbs.) Use new nuts! Page 5863 - Battery tester VAS 1979, VAS 5033, Christie Automotive BT-9000 or equivalent - Switch ignition off - Connect tester leads to battery posts. Tester leads must be securely fastened and make proper contact with the battery posts. - Load current and minimum voltage specifications vary depending on battery capacity. Apply load as per tester instructions, or for 5 seconds at load specified below: If the minimum voltage specification is not reached, replace battery. Load test results A battery is in good condition if the voltage measured during the load test drops gradually and does not fall below the specified value. The rate of decrease varies and depends on the battery capacity and cold cranking amp rating ("cold cranking amps" is the rated ability of the battery to perform at low temperatures and with high loads i.e.: high compression engines). A battery is either faulty or in a low state of charge if the voltage measured during the load test drops quickly and falls below the specified voltage. After performing the load test, a faulty battery will remain below the specified voltage and may only recover very slowly over a long period of time. The no load voltage is never reached. See: Such batteries no longer have sufficient reserve and load capacity and must be replaced. Low Maintenance Batteries, Checking Low Maintenance Batteries With Charge Indicator (magic Eye) And Foil Sealed Cell Caps, Checking Identification Page 3992 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Diagram Information and Instructions Body Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5862 - Excess electrolyte MUST be extracted using a hydrometer - Dispose of electrolyte (sulfuric acid) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal - Remove cell caps from cells with excess electrolyte. - Extract excess electrolyte using hydrometer until electrolyte level is lowered to internal level indicator -1- or external maximum marking. CAUTION! Use use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. Only use genuine cell caps of the same construction if lost or damaged. All cell caps must be equipped with an O-ring seal. Load Testing Load Test WARNING! - Refer to Warnings and Safety Measure. - Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal - DO NOT load test batteries which are gassing. Otherwise there is a risk of explosion. - The following notes and procedures must be followed to ensure correct measurements. NOTE: - In order to better determine a battery's overall condition, it is recommended to always perform the load test in conjunction with the electrolyte specific gravity test. See: Specific Gravity - It is not necessary to remove battery from vehicle or disconnect battery terminals. Special tools, testers and auxiliary items needed Page 1102 set forth by the California Department of Motor Vehicles, vehicle registration information may only be used for recall purposes. Use for any other reason may constitute a violation of state law. Parts information You may receive an initial allocation of parts. During the campaign launch period, parts may be blocked and released by VIN through Special Services. Refer to the VWHub for campaign parts updates. After the launch period, the block may be lifted and then parts can be ordered through your facing parts depot, Time Requirements/Reimbursement Additional Campaigns Some of the affected vehicles may be involved in an additional corrective action. Please check your OTIS View Campaign inquiry screen so that any additional required work can be done simultaneously. Campaign Verification For verification, always check the OTIS View Campaign inquiry screen The OTIS system is the only binding campaign inquiry and verification source; other sources are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as to minimize inconvenience to customers, you are urged to service each vehicle at the scheduled service appointment time, Service Help If you have a question regarding this or any other campaign, please call (800) 741-2919. Dealer Personnel information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Campaign Work Procedure Parts Page 3083 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4235 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1324 - When transmission has been securely supported, remove bolts for transmission carrier (arrows). - Remove pendulum support (arrows). - Lower transmission approx. 60 mm (2.4 in.) -a-. - Disconnect black connector from sensor. - Remove bolt and take sensor -1- out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 3290 Specified value: Infinity ohms If the specified value is not obtained (wires are shorted together): - Repair wiring malfunction according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified value is obtained (wires are not shorted together): - Check wiring to CAN-data bus components for short to battery positive or Ground or open circuit using Current flow diagram: - Check wiring to CAN-Bus for short to battery positive (B+), short to Ground (GND), or open circuit. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Terminal Resistance For CAN-Bus, Checking Terminal Resistance For CAN-Bus, Checking Function The Engine Control Module (ECM) communicates with all databus-capable control modules via a CAN databus. These databus-capable control modules are connected via two data bus wires which are twisted together (CAN_High and CAN_Low), and exchange information (messages). Missing information on the databus is recognized as a malfunction and stored. Trouble-free operation of the CAN-Bus requires that it have a terminal resistance. This central terminal resistor is located in the Engine Control Module (ECM). Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - DTC "P0600 Serial Communication Link" was detected by the Engine Control Module (ECM), Diagnostic mode 3: Check DTC memory. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 3: Check DTC Memory - Ignition switched off. Test sequence - Connect test box to Engine Control Module (ECM), connect test box for wiring test. During this, wiring harness to Engine Control Module (ECM) is not connected. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check the central termination resistor in the Engine Control Module (ECM): - To do this, measure resistance between test box socket 58 + 60: Specified value: 60...72 Ohm If resistance value is not in expected range: - Replace Motronic Engine Control Module (ECM) -J220-. If resistance value is in expected range: - Disconnect test box from Engine Control Module (ECM). - Connect test box to control module wiring harness. - Check CAN data bus wires for short circuit to each other: - To do this, perform a resistance measurement between test box sockets 58 + 60: Specified value: infinite Ohm If specified value is obtained (wires have no shorts): - Eliminate error in wires (see wiring diagram). Specifications Valve Clearance: Specifications Valve clearance Less than 0.2 mm more than 0.1 mm Page 5874 Battery is inserted correctly when center cut-out in battery foot strip aligns with threaded hole in battery carrier -arrows- - On batteries with a hose for central venting ensure that the hose is not squashed. Only then can the battery vent freely. - On batteries without a hose for central venting ensure that the opening on the upper side of the battery cover is not blocked. NOTE: New generation batteries are equipped with a central gas venting system and The grated flame trap. Function: Gases produced during charging escape through a central opening on the side of the upper cover. The integrated flame trap prevents flammable gases in the battery from igniting. The flame trap is comprised of a small round fiberglass mat with a diameter of 15 mm and a thickness of 2 mm. Working as a one-way-valve, it allows gases produced during charging to vent. - Fit battery hold-down bracket and tighten M8 x 30 securing bolt to 22 Nm. - Install positive clamp onto battery positive terminal. NOTE: - Battery terminal clamps must only be fitted by hand without force, this prevents damage to battery housing. - Battery terminals must no longer be greased. - Tighten battery positive terminal clamp securing screw to 6 Nm. - Release elastic cord from fuse holder and slide into mounting. Page 3941 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long and measure battery voltage. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cu.cm/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.2 volts is measured at battery. Since the voltage at the pump is approx. 2 volts less than battery voltage, there is a minimum delivery rate of 200 cu.cm/30 s. If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply line -1- from fuel filter input. NOTE: Depress buttons on hose connections to do so. - Connect pressure gauge (VAG1318) with adapter (1318/17) to hose. - Repeat test of delivery quantity. If minimum delivery rate is obtained now: - Replace fuel filter. If minimum delivery rate is still not obtained: - Remove Fuel Pump (FP) unit and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): Page 8 Alarm Module: Reading and Clearing Diagnostic Trouble Codes With Manufacturer Scan Tool Diagnostic Trouble Code (DTC) Memory, Checking (function 02) NOTE: DTCs stored in memory along with corresponding malfunction descriptions can only be displayed by initiating the On Board Diagnostic program and checking DTC memory (function 02). - Connect VAG 1551 Scan Tool, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 17, "Instrument cluster". - Press -Q- button to confirm input. - Press -> button until "Select function" appears in display. - Switch printer on with -Print- button (indicator lamp in button lights up). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -2- to select "Check DTC memory" function 02. Indicated on display Rapid data transfer Q 02 - Check DTC memory - Press -Q- button to confirm input. The number of stored DTCs appears in the display. X DTC recognized! The number of stored DTCs or "No DTC s recognized" appears in the display and are printed out one after another. - When the last DTC has been displayed and printed out, rectify malfunctions as described in DTC table. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/VAG Code Charts/Immobilizer System If "No DTC recognized" is displayed the program will return to starting point after pressing -> button. No DTC recognized -> Indicated on display Rapid data transfer HELP Select function XX If display reads otherwise: - Press buttons -0- and -6- to select "End Output" function 06. See: Scan Tool Testing and Procedures/Scan Tool Testing/End Output (Function 06) - Switch ignition off and disconnect Data Link Connector (DLC). Without Manufacturer Scan Tool The manufacturer does not provide a procedure for reading diagnostic trouble codes without a scan tool. Clearing Trouble Codes Diagnostic Trouble Code (DTC) Memory, Erasing (function 05) NOTE: After erasing DTC memory its contents will automatically be indicated. If DTC memory cannot be erased, check DTC memory again and repair malfunctions. Requirements - DTC memory has been checked. See: Displaying and Reading Trouble Codes/With Manufacturer Scan Tool - All malfunctions repaired. Page 4486 - Connect diagnostic cable connector to Data Link Connector (DLC). - Switch on tester-arrow-. Note: The tester requires approx. 3 minutes to warm up. - Start engine. - Select zone "Vehicle self-diagnosis" on touch screen. - From this point, tester VAS 5051 guides user further. If V.A.G 1551 is used: - Remove DLC cover -1-. - With ignition switched off, connect V.A.G 1551 Scan Tool with diagnosis cable V.A.G 1551/3A. Page 1495 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 171 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 2894 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6267 1. Pressure line 2. Speed nut 3. Clamp 4. Bolt ^ 22 Nm (16 ft. lbs.) 5. Nut ^ 25 Nm (18 ft. lbs.) 6. Mounting bracket 7. Pressure hose 8. Bolt ^ 22 Nm (16 ft. lbs.) Pressure line (automatic transmission), securing Page 5164 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) 4 Speed Automatic 01M Shift Interlock Solenoid: Service and Repair 4 Speed Automatic 01M Shift lock solenoid -N110-, removing and installing Removing Obtain radio code on vehicles with coded radio. - Disconnect battery Ground strap. - Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7 and remove. Note contact spring for selector lever position display! - Remove locking segment (2 bolts). - Place selector lever in position "1". - Remove retaining bracket -8- (2 nuts). - Remove solenoid securing bolts -9- (Qty. 2) - Remove front selector mechanism securing nuts (Qty. 2). - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. Note: Do not bend or kink the selector lever cable. Page 2284 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the idle speed is not obtained: - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. See: Powertrain Management/Computers and Control Systems/Engine Control Module/Testing and Inspection - Carry out road test. Observe the valid safety precautions when carrying out a road test. See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions/Technician Safety Information - Check DTC memory again. - Repeat idling check. If the specified values are not obtained again: - Check throttle valve control module. - Check intake air system for unmetered air. - Check operating condition of engine. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Operating Conditions, Checking - Check signals from/to air conditioner. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/A/C Compressor Signal, Checking With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Page 501 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 2120 Look for one of these symbols on the front of the oil container, and use only oils that display these symbols. Engine oil additives: VOLKSWAGEN does not recommend the use of oil additives. They may adversely affect your New Vehicle Warranty. Engine oil consumption: The rate of the oil consumption depends on the quality and viscosity of oil, the speed at which the engine is operated, the climate, and road conditions as well as amount of dilution and oxidation of the lubricant. Because of these variables, no standard rate of oil consumption can be established, but drivers should expect higher oil consumption at high speeds and when the engine is new. Notes: ^ The engine in your vehicle depends on oil to lubricate and cool all of its moving parts. Therefore the engine oil should be checked regularly and kept at the required level. ^ Make it a habit to have the engine oil level checked with every fuel filling. ^ Lack of sufficient engine oil may lead to severe engine damage. ^ The oil pressure warning light is not an oil level indicator. Always heed all WARNINGS. See: Maintenance/Service Precautions Page 5880 - Fit battery hold-down bracket and tighten M8 x 25 securing bolt to 22 Nm. - Reinstall insulation jacket where applicable. - Install positive clamp onto battery positive terminal. NOTE: - Battery terminal clamps must only be fitted by hand without force, this prevents damage to battery housing. - Battery terminals must no longer be greased. - Tighten battery positive terminal clamp securing screw to 6 Nm. - Fit fuse holder onto battery and install positive bus onto securing pins on battery positive terminal. - Engage fuse holder clip in battery. - Tighten securing bolt -1- for positive bus on (+) positive terminal clamp. - Connect cables to strip fuses again and tighten securing bolts -A-. - Fit connections -2-. - Only after the fuse holder and positive terminal have been secured should the negative terminal clamp be installed. - Tighten securing bolt to 6 Nm. Page 1567 Alignment: Service and Repair Thrust Angle (Deviation From Direction of Travel), Calculating Thrust angle (deviation from direction of travel), calculating - If alignment readings for rear toe are both positive or both negative (+/+ or -/-), subtract smaller figure from larger figure to determine total toe angle, then divide by 2. Thrust angle (deviation from direction of travel) 5° - Add figures with different prefix (+/-) and divide by 2. Thrust angle (deviation from direction of travel) 10° Individual result is deviation of actual running direction from longitudinal center line of vehicle. Front wheel toe, adjusting If vehicle is out of specification, check trim height and balance if necessary. Page 5678 A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 3918 32 - Connecting Hose. - For crankcase breather. - From breather housing on cylinder head cover. 33 - 2-pin Harness Connector. Black. - For Positive Crankcase Ventilation (PVC) heating element -N79-. - Check heater element voltage supply between terminal - 1 - and -2- with engine running: Specified value: at least 11.5V. 34 - Bracket. Secured to front of oil pan. 35 - Vacuum Reservoir. For intake manifold change-over. 36 - From Secondary Air Injection (AIR) Solenoid Valve - N112 -. Secondary air system. Page 2546 23. To Y-branch of heat exchanger/coolant feed pump Coolant hoses, connection diagram Thermostat Housing, Disassembling and Assembling Note: Routing of hoses at the coolant controller housing. Exploded View 1. Plug 2. O-Ring - Always replace 3. Gasket - Always replace 4. Retaining clamp - Check for tight fit 5. Thermostat housing 6. Bolts. Torque Specification: 10 Nm (7 ft.lbs.) 7. Thermostat Install position: large plate downward Checking: heat controller in water bath Opening starts at approx. 80°C Opening ends at approx. 105°C Travel at least 7 mm 8. Connector 9. Bolts. Torque Specification: 10 Nm (7 ft. lbs.) Page 4942 - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged (dented) dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Fastener/location Tightening torque: Brake caliper to rear axle .............................................................................................................................................................. 65 Nm (48 ft. lbs.) Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 Page 4776 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Locations Air Injection Pump Relay: Locations Component Location Component View Testing and Inspection Tie Rod: Testing and Inspection Tie rod end play, mounts and boots, checking - With vehicle raised (wheels hanging free), check play by moving tie rods and wheels. Specification: zero play - Check mounts. - Ensure boots are correctly seated and not damaged Center position on rack, determining Rack should be centered before installing power steering gear on subframe. Slide rack until dimension -a- is achieved. Dimension -a- = 30.5 mm (1.20 in.). Page 1226 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 1522 Part 2 Recall 06V183000: Brake Light Switch Defect Brake Light Switch: All Technical Service Bulletins Recall 06V183000: Brake Light Switch Defect MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Jetta 1999-2002 Volkswagen/New Beetle 1998-2002 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 06V183000 MFG'S REPORT DATE: May 24, 2006 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 362000 SUMMARY: On certain passenger vehicles equipped with automatic transmissions and cruise controls, a brake light switch on these vehicles may malfunction if it was installed incorrectly during safety recalls 03V-265 OR 04V-096. CONSEQUENCE: The brake lights could become inoperative, or remain on. failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before December 8, 2006. Owners may contact VW at 1-800-822-8987. NOTES: VW recall No. N4. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 3146 Part 2 Page 3317 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 2527 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 6014 Fuse: Application and ID Fuse Arrangements In Fuse Bracket/Battery Fuse arrangements in fuse bracket/battery Page 5020 - V.A.G 1331 Torque wrench - V.A.G 1275 Pliers Selector lever knob and boot, removing and installing Page 953 Outside Temperature Display Sensor: Locations Outside Air Temperature Sensor (Vehicles With Multi-Function Indicator (MFI) Only) G17 - Outside Air Temperature Sensor (Vehicles with Multi-Function Indicator (MFI) only) Page 3080 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6016 Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Page 6210 Alignment: Specifications Vehicle Alignment Specifications Vehicle Data Sticker Example For additional information Vehicle alignment specifications Page 394 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1912 - Pull off wheel bearing/wheel hub unit from stub axle. A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Note: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 . Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 1274 - Check resistance for sensor heater at connector to oxygen sensor terminal 3 + 4. - Specified value: 2.5...10.0 Ohm (at room temperature) If specified value is not obtained: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7. - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 4 + socket 5 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 6-pin connector terminal 3 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 674 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3265 Part 1 Page 382 Daytime Running Lamp Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 1236 Oxygen Sensor: Locations Bank 1, Sensor 2 Oxygen Sensor Oxygen Sensor Location G130 Page 4911 Fig. 9 Clamp for CV joint boot (inner, small dia.), tightening Page 636 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 3114 Clutch Switch: Testing and Inspection With Generic Scan Tool Checking Signal From Clutch Vacuum Vent Valve Switch Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Clutch Vacuum Vent Valve Switch -F36- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Remove driver-side storage compartment. - Disconnect connector from Clutch Vacuum Vent Valve Switch -F36-. Vehicles with 2-pin clutch vacuum vent valve switch - Measure resistance between terminals 1 + 2 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Vehicles with 4-pin clutch vacuum vent valve switch Page 5427 ^ Turn ignition switch to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics" ^ Select "07 - Code control unit" <-- Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J ^ Press the "Q" button to confirm Note: On the display, in the upper right corner, the control module part number and coding are displayed ^ Press <-- button ^ Select "06 - End output" ^ Disconnect VAS 5051 from vehicle ^ Recode radio and reset radio preset stations ^ Reset clock ^ Where applicable, reset power window pinch protection ^ Turn ignition to "OFF" position ^ Proceed to Section E Section E Section E - Brake Bleeding ^ Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING! Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 Note: Capacity Specifications Final Drive Fluid: Capacity Specifications 4 Speed 01M Planetary gearbox fluid Capacity ............................................................................................................................................... ............................ 5.3L (filled for life, no change) Type ....................................................................... .............................................................................................................................................. VW ATF VW Part no. ......................................................................................................................................... ........................................ G 052 162 A1 (0.5 liter) VW Part no. .......................................................... ....................................................................................................................... G 052 162 A2 (1.0 liter) Final drive Initial filling ........................................................................................................................................... .................................................................... 0.75L Oil change ............................................................ .................................................................................................................... Filled for life (no change) Type ..................................................................................................................................................... .................. Gear oil SAE 75W-90 (synthetic oil) VW Part no. ............................................................. .................................................................................................................... G 052 145 A1 (0.5 liter) VW Part no. ......................................................................................................................................... ........................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... ................................................... 7.0L (filled for life) Type ..................................................................................................................................................... ........................................................................... ATF VW Part no. ......................................................................................................................................... ............................................................ G 052 990 A2 Page 6269 Power Steering Pump: Service and Repair Power Steering Pump (Pump In Lower Area), Remove and Install Power steering pump is not serviceable. If malfunction in pump is suspected, determine cause using pressure and leak tests; if malfunctioning replace complete unit NOTE: ^ Pumps supplied as replacement parts are not filled with oil. Therefore, fill pump with hydraulic oil Part No. G 002 000 and rotate by hand, otherwise pump may be damaged or noisy during operation. ^ Type of oil: hydraulic oil Part No. G 002 000 ^ Oil system capacity: 0. 7 - 0.9 ltr. (11. 815.2 oz.). Removing - Remove noise insulation. - Loosen belt pulley hex bolt. Counter-hold with a hex key if necessary. Specifications Compression Check: Specifications Compression pressure New 10 - 13 bar Max. wear 7.5 bar Permissible variation between cylinders 3 bar Page 4124 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams A/T - Pan Gasket Appears to be Leaking Transmission Pressure Test Port: All Technical Service Bulletins A/T - Pan Gasket Appears to be Leaking Group: 37 Number: 01-01 Date: Mar. 5, 2001 Subject: Transmission, Pan Gasket Appears to be Leaking Model(s): New Golf, New Jetta, New Beetle, Cabrio with 4 Speed Automatic Trans. Supersedes T.B. Group Number 37 Number 00-02 to reflect new part number Condition Transmission appears to be leaking around ATF pan gasket. In most cases the leak is NOT caused by the ATF pan gasket, but by the main line pressure plug (arrow). ATF fluid flows down from main line pressure plug to pan seal, giving the appearance of a gasket leak. Note: It is important to note that the 0-ring on the ATF filler pipe is treated with oil during the transmission assembly process and some residual oil may be found around the ATF filler pipe due to this process. This is a normal condition and does NOT indicate a leak. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Service - Clean ATF from transmission surface. - Remove plug and check seal. If seal is damaged: - Replace with Part No: N 904 142 01 (plug with seal) - Tighten main line pressure plug to 12 Nm. DO NOT over tighten plug. Excessive torque will damage the seal. In rare cases, a leak may be caused by a missing bushing in the ATF pan gasket. - Inspect ATF pan gasket for any missing bushings and replace gasket if necessary. Page 3358 - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor behind catalytic converter must be OK. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor After TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals If specified values are obtained: - End diagnosis and switch ignition off. If specified values are not obtained: - End diagnosis and let engine continue to run at idle. - Check primary voltage. Checking primary voltage - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Capacity Specifications Fluid - M/T: Capacity Specifications 02J Manual Transmission Transmission fluid Capacity ................................................................................................................. ................................................................................................... 2.0 liters 02M Manual Transmission Transmission fluid Capacity ................................................................................................................. ................................................................................................... 2.3 liters Page 1738 Fluid - M/T: Fluid Type Specifications 02J Manual Transmission Transmission fluid DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF, G51 ................................................................................. SAE 75w-90 (synthetic oil) DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ............................................................... ...................................................................................................................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Type ....................................................................................................................... .............................................................. G51 SAE 75w-90 (synthetic oil) Page 3300 Rapid data transfer HELP Select function XX - Press buttons -0- and -5- to select "Erase DTC memory" function 05. Indicated on display: Rapid data transfer Q 05 Erase DTC memory - Press -Q- button to confirm input. Indicated on display: Rapid data transfer -> DTC memory is erased! DTC memory is erased. - Press -> button. Indicated on display: Rapid data transfer HELP Select function XX NOTE: - If this appears in the display, the test sequence is faulty. WARNING! DTC memory was not checked - If this appears in the display, the test sequence is faulty. Rapid data transfer -> DTC memory was not checked - Follow test sequence exactly: first check DTC memory, repair malfunctions) if necessary, then erase. Diagnostic Trouble Code Tests and Associated Procedures For information regarding diagnosis of all B, C, P, U and Manufacturer Codes - See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures CAN-Bus Checking Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Page 85 - Antenna cables - New Beetle with Satellite radio (convertible) - Antenna cables - W8 Passat Page 1380 Knock Sensor: Testing and Inspection With Generic Scan Tool Check Knock Sensors NOTE: - Contact surfaces between knock sensor and cylinder block must be free of corrosion, dirt and grease. - For the Knock Sensors to function properly, it is important for tightening torque to be exactly 20 Nm. - Use only gold-plated terminals when servicing terminals in harness connector of knock sensors. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - Knock sensor securing bolt tightened to 20 Nm. - Ignition switched off. Checking resistances and wires (Vehicles with engine code AFP) Knock Sensor (KS) 1 -G61- Disconnect white 3-pin harness connector for knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector for knock sensor 2 (arrow). Page 78 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -8-. ^ Location: Behind rear section of molded headlining. Antennas All models use four antennas items -2-, 4- (qty. 2) & -7-. ^ Antennas (R130, R131) are integrated into rear hatch glass. ^ Antenna R11 in left rear side glass. ^ Antenna R93 in right rear side glass. Antenna amplifiers All models use four antenna amplifiers items -1-, -3-, -5- & -6-. ^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window. ^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid. ^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid. ^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window. Phaeton Page 2705 If specified value is obtained (wires have no shorts): - Eliminate error in wires (see wiring diagram). Page 58 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -8-. ^ Location: Behind rear section of molded headlining. Antennas All models use four antennas items -2-, 4- (qty. 2) & -7-. ^ Antennas (R130, R131) are integrated into rear hatch glass. ^ Antenna R11 in left rear side glass. ^ Antenna R93 in right rear side glass. Antenna amplifiers All models use four antenna amplifiers items -1-, -3-, -5- & -6-. ^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window. ^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid. ^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid. ^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window. Phaeton Page 5245 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Page 863 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Page 3050 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 2759 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. A/C Pressure Switch F129 High Pressure Sensor / Switch: Description and Operation A/C Pressure Switch F129 A/C Pressure Switch F129 This pressure switch has 3 functions: 1. Switches coolant fan to next higher stage upon pressure increase in refrigerant circuit (approx. 16 bar). 2. Switches off A/C system if pressure is excessive (approx. 32 bar), e.g. because of insufficient engine cooling. 3. Switches off A/C system if pressure is insufficient (approx. 2 bar), e.g. loss of refrigerant. NOTE: A/C Pressure Switch F129 replaces the A/C Refrigerant High Pressure Switch F23, A/C Refrigerant Low Pressure Switch F73 and the A/C Refrigerant High Pressure Switch F118. Intake Manifold Upper Section, Disassmbling and Assembling Intake Manifold: Service and Repair Intake Manifold Upper Section, Disassmbling and Assembling NOTE: For additional information regarding the Removal and Installation procedure please refer to: Vehicle /Engine, Cooling, and Exhaust /Engine / Cylinder Head Assembly /Valve Cover / Service and Repair. See: Cylinder Head Assembly/Valve Cover/Service and Repair Intake Manifold Upper Section, Disassembling and Assembling 1 - Intake manifold upper section For Removing and Installing procedures refer to: Vehicle /Engine, Cooling, and Exhaust /Engine /Cylinder Head Assembly /Valve Cover / Service and Repair. See: Cylinder Head Assembly/Valve Cover/Service and Repair 2 - Oil Seal Always replace. 3 - Bearing Cap For intake manifold change-over barrel. Page 1452 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4369 - Turn piston slightly when installing 11. Clutch housing with turbine shaft - There are two different types - Height varies according to number of inner and outer plates 12. O-ring - Always replace - Installing see Fig. 4 13. Piston ring - Check that it is correctly located see Fig. 2 - Installing see Fig. 3 Fig. 1 Removing and installing circlip (arrow) - Press down carefully on piston cap until circlip can be installed. Fig. 2 Checking seating of piston rings A piston ring is installed on the pump shaft inside the clutch housing (arrow). Ensure that ends of piston rings are hooked together. Fig. 3 Fitting and hooking ends of piston ring together Page 3410 Electronic Throttle Control Module: Testing and Inspection Throttle Valve Control Module J338, Checking With Generic Scan Tool Throttle Valve Control Module, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of throttle valve control module. Function The throttle valve activation occurs via an electric motor (throttle drive) in the throttle valve control module. It is activated by the Engine Control Module (ECM) according to specifications of the two sensors, Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-, function of the E-gas system. Components of Throttle Valve Control Module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1- for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for throttle drive (power accelerator actuation) -G188Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Throttle valve must not be damaged or dirty. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 17: Throttle valve position (absolute)." - Check specified value of throttle valve position (absolute) at idle stop: Page 2629 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 6364 Steering Wheel: Programming and Relearning Code Control Module (Function 07) Use this function to code the Multi-function Steering Wheel (MSW) electronics according to various equipment variations available. Coding - Connect VAG 1551 Scan Tool (ST), input address word 16 "Steering wheel electronics" and then press -> button, until "Select function XX" is shown in display. Indicated on display (select function): Rapid data transfer Help Select function XX - Press buttons -0- and -7- to select "Code control module" function 07". - Press -Q- button to confirm input. - Indicated on display: Coding control module Enter code number XXXXX (0-32000) - Check/enter applicable code number from code table using model and equipment particulars. Code table Code Number Designation 00007 Radio (only) 00008 Radio & cruise control system (CCS) Coding example: 00008 = vehicles fitted with radio and cruise control system. - Indicated on display (example only): Coding control module Q Enter code number 00008 (0-32000) - Press -Q- button to confirm input. Indicated on display (select function): Rapid data transfer HELP Select function XX Check DTC memory after coding, and erase any DTCs stored. - End output (function 06). Page 5696 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Ribbed Belt, Removing and Installing Ribbed Belt: Service and Repair Ribbed Belt, Removing and Installing Ribbed Belt, Removing And Installing NOTE: - Always replace ribbed belt if found to be faulty. This will avoid related break-downs or operating problems. - If a used ribbed belt is to be reused, mark direction of rotation before removing. When installing used ribbed belts observe the direction of rotation marked on removal. Installing opposite to the direction of rotation leads to belt damage - It is not necessary to adjust the ribbed belt tension, as a spring loaded tensioner guarantees the best possible belt tension Preparation, all engines - Remove securing bolts -arrows- and remove the middle cover of the engine compartment noise insulation. - Remove hex nut, unclip securing clips -arrows- and remove right-hand engine cover of the compartment noise insulation. All gasoline engines, continued: - Mark direction of rotation of ribbed belt if it is to be reused. Page 2209 - Remove upper tensioner bolt. Fuse Arrangements In Fuse Holder, Instrument Panel Left Fuse: Application and ID Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 2544 6. Cable guide - For coolant hoses and wiring harness. 7. 8 Nm 8. Upper coolant hose - To top off radiator. - Check for secure seating. 9. Bracket - For wiring harness. 10. Lower coolant hose - From bottom of radiator. - Check for secure seating. 11. To cylinder block 12. After-Run Coolant Pump -V51- Secured to cylinder block by a bracket. 13. Oil cooler 14. O-ring - Replace. 15. From cylinder block 16. Coolant pipe 17. Sealing plug, 2 Nm 18. Coolant pump - Observe installation position. - Check for ease of movement. - If damaged or leaking replace complete. 19. 20 Nm 20. Belt pulley - For coolant pump. 21. 20 Nm - Use Water Pump Wrench -VAG 1590- to loosen and tighten. 22. 25 Nm 23. Expansion tank - Perform leak test on cooling system with Cooling System Tester -VAG 1274- and Adapter -VAG 1274/8-. - Test pressure: 1.4 to 1.6 bar. 24. Seal - Replace if damaged. 25. Sealing Cap - Check with Cooling System Tester -VAG 1274- and Adapter -VAG 1274/9-. - Pressure relief valve must open at a pressure of 1.5 to 1.6 bar. 26. Seal - Replace. 27. Thermostat housing Page 2803 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor -G70-, item 4. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Electrical / Mechanical Repair Wheel Bearing: Electrical / Mechanical Repair Rear Wheel Bearing Press for VW/Audi AST tool# 3420 VW/Audi Rear Wheel Bearing Press Applicable to Newer Golf, Jetta and New Beetle 2008 suggested user price: 25.92 Assenmacher Specialty Tools 1 800 525 2943 Page 2458 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 5360 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 1272 - Check resistance for sensor heater at connector to oxygen sensor terminal 1 + 2. Specified value: 6,4...47,5 Ohm (at room temperature) If specified value is not obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-: Vehicles with engine code AFP, item 9. - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check Ground (GND) activation of oxygen sensor heater. - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 4-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Terminal 2 + socket 63 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 4-pin connector terminal 1 and Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4172 Control Module: Testing and Inspection 4 Speed Automatic 01M Control Module Pin Out Values Transmission Electrical Check Special tools, testers, etc. - Fluke (R) 83 Digital multimeter or equivalent - VAG 1594 A Adapter set - VAG 1598/18 Test box Test requirements: - Battery voltage OK - Vehicle voltage supply OK - Fuses No. 7, 11, 15 and 31 OK - Fuse in main fuse box (110 amps) OK - Ground connections for transmission OK Ground connection points are located in the plenum area of the cowl and below the battery in the engine compartment. - Check battery Ground strap and Ground strap between battery and transmission. Electrical check Page 5042 1. Gear selector lever 2. Relay lever Recall 04V584000: Hazard Switch/Relay Replacement Hazard Warning Switch: Recalls Recall 04V584000: Hazard Switch/Relay Replacement MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Golf 2000-2002 Volkswagen/GTI 2000-2002 Volkswagen/Jetta 2000-2002 Manufacturer: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 04V584000 RECALL DATE: Dec 13, 2004 COMPONENT: Exterior Lighting: Hazard Flashing Warning Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 350000 SUMMARY: On certain passenger vehicles, the hazard switch and flasher system function may degrade over time because of distortion and material transfer of the contacts of certain hazard switch relays which occurs due to substantially increased electrical current load from higher wattage turn signal bulbs. CONSEQUENCE: This may result in intermittent or inoperative turn signal and hazard flasher function. REMEDY: Dealers will replace the hazard flasher switch/relay kit. The recall is expected to begin during february 2005. Owners should contact Volkswagen at 1-800-822-8987. NOTES: VW recall No. VX. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). With Manufacturer's Scan Tool Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Manufacturer's Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: The Engine Control Module (ECM) will use the intake air temperature as a replacement value for an engine start (start temperature replacement value) as soon as there is a malfunction stored in DTC memory which affects the Engine Coolant Temperature (ECT) sensor -G62-. The temperature then rises according to a model stored in the control module. When the engine has reached normal operating temperature, a fixed replacement value will be displayed after a certain period. This fixed value is also dependent upon the intake air temperature. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Engine cold Test sequence NOTE: Only gold plated contacts must be used to repair contacts -1- and -3- in the harness connector for the coolant temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read off coolant temperature value in display field 3. - Start engine and run at idle. Temperature value must increase uniformly. Compiled From Every Wiring Section 1998-2004 Starter Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3479 - Read off supply voltage for Engine Control Module (ECM) in display field 2. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Evaluating display group 4, display field 2 - control module voltage supply Page 2201 6800TDI - TDI Timing Belt Tool Set Additional Tools Possibly Required: 3359 - TDI Lock Pin Page 4035 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 3076 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 6194 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 4041 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Page 3267 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Diagrams Ribbed Belt: Diagrams 6-cylinder Engine With Power Steering Pump And A/C Compressor 1 - Tensioning pulley 2 - Pulley - Generator (GEN) 3 - Ribbed belt - pulley, generator, compressor for air conditioner, vane pump for power steering, crankshaft/vibration damper and coolant pump 4 - Pulley - A/C compressor 5 - Pulley - power steering pump 6 - Crankshaft/vibration damper/pulley 7 - Pulley - coolant pump Page 2229 If cylinder 1 is correctly at TDC position, it will be possible to see a slot - arrow - on intermediate shaft sprockets. If the slot is not visible: - Turn crankshaft one turn in direction of rotation of engine. Note: If the crankshaft is turned with the cylinder head removed, a second mechanic must guide the camshaft roller chain by hand to prevent blocking. - Set both camshafts to TDC of cyl. 1. Page 4773 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 3077 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3828 Fuel Pressure: Specifications Residual Pressure After 10 minutes there must be a residual pressure of at least ................................................................................................................................ 2.0 bar. Page 3490 Engine Control Module: Service and Repair Replacement ECM, Adaptation (Function 10) Replacement Engine Control Module (ECM), Adaptation (function 10) NOTE: - The engine control module is adapted to the immobilizer control module in the instrument cluster. When changing a component it must be readapted. - If an authorized ignition key is not available but the secret number is, new ignition keys must be manufactured and adapted. - The adapting can be interrupted with the "C" button of VAG 1551 Requirements Authorized ignition key available. - Insert old (authorized) key in ignition lock. - Connect VAG 1551, select operating mode 1, "Rapid data transfer". Switch ignition on and enter address word 17, "Instrument cluster". After control module identification has been displayed: Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select function 10, "Adaptation". Indicated on display Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display Adaptation Enter channel number XX - Press button -0- twice to select "Channel O". - Press -Q- button to confirm input. Indicated on display Adaptation Q Erase learned value? - Confirm entry with -Q- button. Indicated on display Adaptation -> Learned values are erased - Press -> button. Indicated on display Rapid data transfer HELP Page 2645 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Connect multimeter to measure voltage at terminals -2- and -6-. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. - Connect multimeter to measure voltage at harness connector terminal -2- and Ground. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4725 - Insert selector lever cable -3- in mounting bracket and press onto selector lever -2-. - Fit new selector lever cable locking plate -1- on mounting bracket. Installation position: Angled end of locking plate must point toward end of selector lever cable. Insert complete selector mechanism with selector lever cable in tunnel underside. - Screw in bolts -arrows B- by hand. - Tighten front of selector mechanism (2 nuts) to 25 Nm. - Shift selector lever from "P" to "2". Selector lever mechanism and selector lever cable must move freely. If necessary replace selector lever cable or service selector lever mechanism. - Shift selector lever into "P" position. - Tighten nuts -arrows A- to 10 Nm. - Tighten both bolts -arrows B- to 25 Nm. Note: When doing this, ensure seal remains seated correctly. - Insert protective sleeve of selector lever cable in cover. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. Page 6370 - If five punch indentations are on the bolt, it must be replaced with a new one. Control Module For Multi-Function Steering Wheel Remove/Install Control Module For Multi-Function Steering Wheel -J453-, Removing And Installing CAUTION! Before working on the electrical system: - Determine the correct coding for the anti-theft radio. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio, Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. Removing - Remove lower footwell cover to gain access to 13 position relay carrier. Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor: Locations Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor Location G39 Brake Pads (Rear) - Apparent Premature Wear Brake Pad: All Technical Service Bulletins Brake Pads (Rear) - Apparent Premature Wear Group: 46 Number: 02-01 Date: Apr. 15, 2002 Subject: Rear Brake Pads, Appear to be Worn Prematurely Model(s): Golf, Jetta, New Beetle 2000, 2001 Cabrio 2001 Supersedes T.B. Group 46 Number 00-01 dated Nov. 27, 2000 Condition While inspecting front and rear brake pads, the rear brake pads appear to be prematurely worn. May be caused by aggressive brake pedal application and a softer brake pad composition. Service When inspecting a customer's brake system: If rear brake pads appear to be prematurely worn: - Inspect front brake pads. If front pads are original (factory) pads and are still good. - Install new rear brake pads Part No: 1J0 698 on vehicle, See appropriate Repair Manual CD-ROM, Group 46 - Rear Wheel Brakes Disc brakes, serving". CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. When procedure applies to vehicles within the first 12 months or 12,000 miles/20,000 km, (whichever occurs first) of the Limited New Vehicle Warranty period, use the table shown. Note: For vehicles which have exceeded 12 months or 12,000 miles/20,000 km (whichever occurs first) of the Limited New Vehicle Warranty period, contact your FOM. Page 2967 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. Page 5231 Test Step 7 - 15 Page 6220 Alignment: Service and Repair Thrust Angle (Deviation From Direction of Travel), Calculating Thrust angle (deviation from direction of travel), calculating - If alignment readings for rear toe are both positive or both negative (+/+ or -/-), subtract smaller figure from larger figure to determine total toe angle, then divide by 2. Thrust angle (deviation from direction of travel) 5° - Add figures with different prefix (+/-) and divide by 2. Thrust angle (deviation from direction of travel) 10° Individual result is deviation of actual running direction from longitudinal center line of vehicle. Front wheel toe, adjusting If vehicle is out of specification, check trim height and balance if necessary. Page 1847 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1442 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. Page 3616 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the oxygen sensor control in display field 1 does not fluctuate as stated: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values in display field 1 are not obtained even after a road test or the value does not fluctuate by at least 2 %: - Check oxygen sensor (before Three Way Catalytic Converter (TWC)) aging. Evaluating display field 32, display field 1: Oxygen sensor learned values before Three Way Catalytic Converter (TWC) Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. Page 4234 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5780 ^ VAS 1978 Wiring harness repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery ^ Disconnect wheel speed sensor wiring connector. ^ Remove rear interior side Panel trim. ^ Strip insulation (arrow) from shrink connection. ^ Cut speed sensor wiring in front of spliced connection with stripping pliers from VAS 1978 wiring repair kit and remove faulty wiring. ^ Strip insulation at wiring end by 15 mm (5/8 inch) using stripping pliers from repair kit and fold over stripped wire portion. ^ install new speed sensor wiring. ^ Connect wheel speed sensor to speed sensor wiring. With Manufacturer's Scan Tool Intake Air Temperature Sensor: Testing and Inspection With Manufacturer's Scan Tool Intake Air Temperature Sensor -G42- Checking NOTE: The Intake Air Temperature (IAT) sensor -G42- is a part of the Mass Air Flow (MAF) sensor -G70- and cannot be replaced separately. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram - VAG1921 hose clip pliers - Chilling spray (commercially available) Test sequence NOTE: Only gold plated contacts must be used to repair The contacts in the intake air temperature sensor. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 - Read intake air temperature value in display field 4. Page 1283 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 5843 Battery: Environmental Impact Information 6 Disposal: Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal. 7 Never dispose of old batteries in household waste! 8 Danger of explosion: A highly explosive gas is produced when charging batteries. Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 987 ^ EXAMPLE of INCORRECTLY installed switch. Internal stop pin (white arrow) is NOT seated fully against outer shell (black arrow). ^ EXAMPLE of CORRECTLY installed switch. Internal stop pin (white arrow) is seated fully against outer shell (black arrow). - Connect brake switch connector. Operate brake pedal to verify proper function, then reinstall lower cover panel. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. 4 Speed 01M Transmission Fluid - A/T: Testing and Inspection 4 Speed 01M Transmission ATF Level, Checking and Topping Up Special Tools and Equipment - VAG 1551 Scan Tool. - VAG 1551/3 Cable. - VAG 1924 Reservoir. VW ATF is obtainable as a spare part: Container size 0.5 ltr. - Part No. G 052 162 A1. - Container size 1.0 ltr. - Part No. G 052 162 A2. - Always replace seal (arrow) when checking ATF level. Page 5227 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 1685 Final Drive Fluid: Fluid Type Specifications 4 Speed 01M Planetary gearbox fluid Capacity ............................................................................................................................................... ............................ 5.3L (filled for life, no change) Type ....................................................................... .............................................................................................................................................. VW ATF VW Part no. ......................................................................................................................................... ........................................ G 052 162 A1 (0.5 liter) VW Part no. .......................................................... ....................................................................................................................... G 052 162 A2 (1.0 liter) Final drive Initial filling ........................................................................................................................................... .................................................................... 0.75L Oil change ............................................................ .................................................................................................................... Filled for life (no change) Type ..................................................................................................................................................... .................. Gear oil SAE 75W-90 (synthetic oil) VW Part no. ............................................................. .................................................................................................................... G 052 145 A1 (0.5 liter) VW Part no. ......................................................................................................................................... ........................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... ................................................... 7.0L (filled for life) Type ..................................................................................................................................................... ........................................................................... ATF VW Part no. ......................................................................................................................................... ............................................................ G 052 990 A2 Page 3605 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Continuation With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 2147 Engine Oil Pressure: Pressure, Vacuum and Temperature Specifications Engine Oil Specifications At Idle And An Oil Temperature Of 80°C Oil Pressure ......................................................................................................................................... ................................................... 2.0 Minimum At 2000 RPM And An Oil Temperature Of 80°C Oil Pressure ......................................................................................................................................... .................................. 3.0 to 4.5 Bar Minimum At Higher RPM With Oil Temperature Of 80°C: Oil Pressure ......................................................................................................................................... ................................ Must Not Exceed 7.0 Bar Page 3530 Clutch Switch: Testing and Inspection With Generic Scan Tool Checking Signal From Clutch Vacuum Vent Valve Switch Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Clutch Vacuum Vent Valve Switch -F36- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Remove driver-side storage compartment. - Disconnect connector from Clutch Vacuum Vent Valve Switch -F36-. Vehicles with 2-pin clutch vacuum vent valve switch - Measure resistance between terminals 1 + 2 of switch. Specified value Clutch pedal not depressed: max. 1.5 Ohm Clutch pedal depressed: infinite Ohm Vehicles with 4-pin clutch vacuum vent valve switch Service and Repair Shift Boot: Service and Repair 5 Speed Manual 02J Separating and Assembling Boot From Gear Lever Knob 1. Gear shift knob - Screw on and off together with boot 2. Boot collar 3. Boot with frame - Remove and install together with gear shift knob - Separating from gear shift knob = Fig. 1 - Connect to gear shift knob before installing Fig. = 1 4. Clip 5. Bushing 6. Clamp - To secure gear shift knob on gear lever 7. Cover 8. Hex nut, 25 Nm 9. Floor plate 10. Retainer - For gear lever housing 11. Gasket - Between selector housing and floor - Self adhesive Bond to gear lever housing Page 3234 - Read off supply voltage for Engine Control Module (ECM) in display field 2. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Evaluating display group 4, display field 2 - control module voltage supply Page 2493 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5982 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2891 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 6458 - Pull off wheel bearing/wheel hub unit from stub axle. - A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Caution: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 ab. - Use a new 12-point nut - A - and tighten to 175 Nm (129 ft. lbs.). - Install brake disc. Page 689 Wiper Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 3242 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Replacing Engine Control Module (ECM), Replacing Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Removing - First print out control module identification and thereby previous control module coding as follows: - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. The control unit identification and coding are indicated on the display, e.g.: 021906018B MOTRONIC ME7.1 G V06 -> Coding 00000 WSC 00000 - Print out control module identification by pressing scan tool PRINT button. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove wiper arms and plenum chamber cover. - Release harness connector from control module and disconnect. - Press retaining tab (arrow) to left and remove control module. Installing - Place new control module into retaining frame. - Install control module harness connector and lock. - Check previous coding and coding of new control module. - Adapt ECM to immobilizer. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt new control module to throttle valve control module. - Activate cruise control system. - Check idle speed. - Generate readiness code. Page 5774 ^ Disconnect wheel speed sensor wiring connector -1-. ^ Remove bolt -2- from wheel bearing housing. ^ Remove wheel speed sensor from wheel bearing housing. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat sensor with lubricant G 000 650. ^ Insert speed sensor into mounting hole in wheel bearing housing and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor wiring connector. ^ Turn wheels fully to left and right lock and check clearance of speed sensor wiring. ABS wheel speed sensor rotor for front axle, checking ^ Raise vehicle. ^ Remove wheel. ^ Rotate brake disc and check whether wheel speed sensor rotor is damaged or dirty. ^ If rotor is damaged, remove wheel hub with rotor and replace. ^ Raise vehicle. ^ Remove wheel. ^ Turn wheel hub and measure distance between rotor and speed sensor, -dimension a, all around. Dimension a = 0.3 mm (0.0118 in.) ^ If the rotor is not true, remove wheel hub with rotor and replace. Page 1303 Page 2860 - Press buttons -0-, -4- and -1- to input display group number 41 (041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 2. Page 208 Page 364 Control Module HVAC: Description and Operation Climatronic Notes Climatronic control unit -J255-, A/C control head -E87- and instrument panel temperature sensor -G56- with interior temperature sensor blower -V42- are integrated into a single unit and cannot be serviced separately. Page 6074 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 562 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Replacing Engine Control Module (ECM), Replacing Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Removing - First print out control module identification and thereby previous control module coding as follows: - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. The control unit identification and coding are indicated on the display, e.g.: 021906018B MOTRONIC ME7.1 G V06 -> Coding 00000 WSC 00000 - Print out control module identification by pressing scan tool PRINT button. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove wiper arms and plenum chamber cover. - Release harness connector from control module and disconnect. - Press retaining tab (arrow) to left and remove control module. Installing - Place new control module into retaining frame. - Install control module harness connector and lock. - Check previous coding and coding of new control module. - Adapt ECM to immobilizer. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt new control module to throttle valve control module. - Activate cruise control system. - Check idle speed. - Generate readiness code. Service and Repair Reverse Gear Shaft: Service and Repair For further information regarding this components and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Page 5997 Fuse arrangements in fuse bracket/battery Page 1479 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3079 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2477 1. Coolant recovery bottle 2. Upper coolant pipe 3. Throttle valve control unit J338- 4. Heat exchanger for heating 5. Check valve 6. After-run coolant pump -V51- 7. ATF radiator,only vehicles with automatic transmission 8. Upper coolant hose 9. Radiator 10. Lower coolant hose 11. Thermostat housing 12. Lower coolant pipe 13. Oil cooler 14. Auxiliary radiator 15. Coolant pump 16. Cylinder block 17. Cylinder head Page 3673 Vehicle Speed Sensor: Locations Vehicle Speed Sensor (VSS) G68 - Vehicle Speed Sensor (VSS) Page 3125 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 6066 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 2945 Throttle Position Sensor: Testing and Inspection With Generic Scan Tool Throttle Position (TP) Sensor, Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirement - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. Function Both the Throttle Position (TP) Sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently of each other. Both sensors are stored in one housing. Test sequence NOTE: When servicing terminals in the harness connector for the Throttle Position (TP) Sensor, use only gold-plated terminals. - Remove footwell cover (driver's side). - Disconnect 6-pin connector from Throttle Position (TP) Sensor. - Switch ignition on. Checking voltage supply and wiring to control module - Connect multimeter to the following connector terminals for voltage measurement. Terminal 1 + Ground (GND) Terminal 1 + 5 Terminal 2 + Ground (GND) Terminal 2 + 3 Specified value: at least 4.5 V - Switch ignition off. Page 1053 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 4183 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 3648 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 5682 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Specifications Intake Manifold: Specifications Information not supplied by the manufacturer. Page 6065 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 4915 Constant Velocity Joint: Service and Repair Triple-Rotor Joint, Disassembling and Assembling Special tools and equipment - VW 426 Tube - 40-204A Block - 3340 Pliers - VW 161A Triple-rotor joint, disassembling and assembling Disassembling - Open clamp. - Open clamp on shaft and slide protective boot back. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5860 - Unscrew cell caps -2-. - Look into individual battery cells to determine electrolyte level. - Electrolyte level must align with the internal electrolyte level indicator (lip) -1-. This equates to the external "maximum" marking on the battery case. NOTE: On batteries with black housings, obtain accurate electrolyte level readings by illuminating inside of cells with a flashlight See: See: Electrolyte level too low - Fill with distilled water using battery filling bottle VAS 5045 (or equivalent) up to the max. marking NOTE: Page 1402 Impact Sensor: Service and Repair Driver's/Front Passenger's Side Airbag Crash Sensor Driver's/front Passenger's Side Airbag Crash Sensor, Removing And Installing 1 - Side airbag crash sensor, driver's -G179-/front passenger's -G1802 - Connector 3 - Bolt 6 Nm 4 - Carpet - Disconnect battery ground (GND) strap. - Remove driver's or front passenger's seat (Airbag - use adapter VAG 5061). - Release carpet -4- and insulation mat in area of sensor. - Disconnect connector -2- and remove screws -3Installation - Install in reverse order of removal. - Reassemble carpet. - Install seat and connect connectors. With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 4722 - Slide sleeve -1- downward. - Pull button -2- out of handle -3- just enough so that pull lever-arrow- hangs down. - Pull handle off selector lever. Installing Shift selector lever to position "R". - Pull button -2- out of handle -3- just enough so that pull lever -arrow- hangs downward. - Press handle on selector lever onto stop. Installation position: Button points to driver. - Pull button out slightly and guide pull lever -arrow- into handle. - Press button so that pull lever engages in pull rod -4-. Button must now spring back onto stop. - Slide sleeve -1- upward in twisting motion until two wide tabs of sleeve locate in slots of handle and sleeve can be felt to engage in handle. - Set selector lever in position "P". Selector Mechanism Removing and Installing Page 4842 - Remove power steering line -2- from front of transmission (arrows). - Remove retainer -3-. - Remove power steering line from rear of transmission (in area of pendulum support) and tie to one side. - Remove retaining bracket from valve body cover. - Remove pendulum support (arrows A and B). - Position tensioning strap T10038 around stabilizer bar -1- and right-hand drive shaft -2-. - Pull engine/transmission assembly onto stabilizer bar. - Carefully pry off breather cap -1-. - Remove bolts from valve body cover -2-. - Using a screwdriver (for example), carefully lift valve body cover off transmission housing. Page 5046 Fig. 1 Separating cover from gear shift knob and assembling to gear shift knob Turn boot inside out. - Carefully pry clamping sleeve (arrow) off with a screwdriver and pull gear shift knob out. Installation is carried out in the reverse sequence. Also, note the following: Insert gear shift knob in cover. - Push clamping sleeve onto gear shift knob and engage. - Install gear shift knob and boot together. Locations Brake Fluid Pressure Sensor/Switch: Locations G201 - Brake Pressure Sensor 1 (vehicles with ESP) Page 4348 Shift Interlock Solenoid: Service and Repair 5 Speed Automatic 09A Shift lock solenoid -N110-, removing and installing Removing Check whether a coded radio is fitted. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - Switch ignition off and disconnect battery Ground strap. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - -Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Unclip shift lock solenoid -N110- from retainer arrows A-. - Pull solenoid out of locking pawl -arrow B-. Page 946 Fuel Gauge Sender: Service and Repair Fuel Level Sensor, Removing And Installing Removing - Remove fuel delivery module. - Unlock and remove attachment plugs for lines -3- and -4-. - Lift tabs -1 - and -2- with a screwdriver and remove fuel level sensor from below -arrows-. Installing - Insert fuel level sensor into delivery module guides and press upwards until they click into position. - Install fuel delivery module. Page 1679 - Also pull coolant hose out from oil cooler -arrow- to drain coolant from engine. Note: Please follow regulations for disposal! Refilling Notes: To satisfy TL VW 774 D, only G 12 may be used as a coolant additive. Color coding: red. - Never mix G 12 with any other coolant additives! - If the liquid in the coolant recovery bottle is brown, this means that G 12 was mixed with another coolant and the coolant has to be changed. - G 12 and additives which are labeled "satisfies TL VW 774 D" prevent damage from freezing and corrosion and prevent lime deposits. They also raise the boiling point For these reasons, the cooling system must be filled with antifreeze and anti-corrosion agents throughout the year. - The coolant's higher boiling point will contribute to operational reliability under higher engine loads, especially in tropical climates. - The antifreeze protection must go down to - 25° C (in Arctic climates down to -35°a C). - The concentration of the coolant may not be reduced by topping up during the warm seasons or in warm countries. The proportion of additive must be at least 40%. - If the climate requires stronger antifreeze protection, the portion of G 12 can be increased, but never above 60% (antifreeze protection down to about -40° C), otherwise the antifreeze protection will begin to decrease again and the cooling effect will be reduced. - Do not reuse the same coolant if the radiator, heat exchanger, cylinder head or cylinder head gasket have been replaced. Recommended mixing ratios 1) The amount of coolant may vary depending on the vehicle accessories. - Tighten drain plug into radiator return. - Push coolant hose onto oil cooler connection and pull it tight. Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4316 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 191 Power Seat Relay: Electrical Diagrams For information regarding diagrams for the Power Seat Relay, please refer to Memory Positioning Systems / Diagrams. Page 6549 Air Door Cable: Service and Repair Footwell/Defroster Flap Cable, Installing and Adjusting Cables, Installing And Adjusting Footwell/defroster flap cable, installing and adjusting Prerequisite: - Heating and ventilation controls are installed. Adjusting - Turn air distribution rotary knob to left to stop. - Attach wire end of cable -1- to temperature flap lever -3-, arrow -A-. - Push footwell/defroster flap lever to stop -arrow C- and attach outer cable -1with clip - 2-, -arrow B-. - Turn air distribution rotary control knob to left and right to stops. - When turning the rotary control knob, both end stops must be reached. Page 5167 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 3063 - Perform resistance measurement on Intake Air Temperature (IAT) sensor -G42-, terminals -1(signal) and 3 (Ground (GND)). Scale -A- shows resistance values for temperature range 0-50 °C and scale -B- shows the values for temperature range 50-100 °C. Examples: - 30 °C is in range -A- and corresponds to a resistance of 1.5-2.0 Kohms - 80 °C is in range -B- and corresponds to a resistance of 275-375 Kohms If the specified value is not obtained: - Replace Mass Air Flow (MAF) sensor -G70-, item -24-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 3327 Page 694 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams With Manufacturer's Scan Tool Catalytic Converter: Testing and Inspection With Manufacturer's Scan Tool Catalytic converter, checking Special tools, equipment, test and inspection devices; required accessories - V.A.G 1551 scan tool Note: The VAG 1552 system tester may also be used in place of the V.A. G 1551 scan tool, except that no printout can then be made. - V.A.G 1551/3 cable Test sequence - Connect VAG 1551 (or VAG 1552) scan tool. Leave engine running and select engine control unit using "address word" 01. Diagnosing the aging of oxygen sensors (sensor dynamics) Indicated on display Press keys "0" and "4" for function "start basic setting" and acknowledge entry with "Q". Indicated on display Press "0", "3" and "4" for display group 34 and acknowledge with "Q". Page 1462 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2804 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Check wiring between test box and 5-pin harness connector -1- for open circuit according to wiring diagram. Terminal -1- + socket 26 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Check wiring additionally for short circuit to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: Page 2254 NOTE: The camshafts do not have timing marks, special tool 3268 is required to time camshafts. Please see Timing Chain / Service and Repair for complete procedures to set/adjust the camshaft, intermediate shaft and Crankshaft timing alignment. See: Timing Chain/Service and Repair. Engine Controls - Silicone Sealer/Lubricant Precautions Oxygen Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Suspension - Insufficient Data On Vehicle Label Alignment: Technical Service Bulletins Suspension - Insufficient Data On Vehicle Label Condition Vehicle Data Label, Suspension PR. Numbers Missing To properly align the vehicle, the PR. number must be used to identify the correct vehicle alignment specifications. Specifications can be found in the Repair Manual - Repair Group 44. 44 06 09 Aug. 28, 2006 2005561 Supersedes T.B. Group 44 number 03-01 dated April 15, 2003 due to updated information. Technical Background Insufficient information on label. Production Solution PR. numbers are included on Vehicle Data Label as of: - Jetta - VIN: 3VWSK69M43M098184 (approx. build date 11/12/2002). - New Beetle - VIN: 3VWCD21C23M428513 (approx. build date 11/12/2002). For vehicles produced prior to the above VINs, the PR. number may be missing from the label. Service Page 4389 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 1092 Page 6564 - Install felt strips on both sides of the center air outlet at white arrows directly behind locking points (black arrows) as shown. Note: DO NOT cover locking points (black arrows). - Reinstall center air outlet. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 6509 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Raise vehicle. - Remove wheel. - Reset brake - To do this use a screwdriver through the opening in brake drum and push adjuster upward. - Remove phillips-head screw for brake drum and take out brake drum. - Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove 12-point nut. Page 5263 Downshift Switch: Service and Repair 4 Speed Automatic 01M Fig. 24 Kickdown switch -F8Removing and installing kick down switch Gasoline engine The accelerator cable must be removed to be able to remove and install the kick-down switch. Readjust the accelerator when installing. Page 4903 - Remove bolts (arrows). - Press axle shaft out. NOTE: When pressing axle shaft ensure sufficient clearance is available. - Do not allow drive axle to hang by inner CV or triple-rotor joint to avoid damaging bearing surfaces. Tie drive axle to stabilizer bar or other suspension component if it is to remain attached to drive flange. - Do not flex inner CV or triple-rotor joint more than 25 degrees from its original angle. - Remove axle shaft. The following sequence applies to automatic transmission vehicles only - Remove bolts (arrows). - Remove left noise insulation if equipped. Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 3906 - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Engine speed (RPM) sensor must be OK, checking. See: Computers and Control Systems/Engine Speed Sensor/Testing and Inspection - Ignition switched off. Test sequence Vehicles with engine code AFP - Remove intake manifold upper part, item 2 . NOTE: Seal the intake channels in intake manifold lower part and in cylinder head using a clean rag. Vehicles with engine code BDF - Remove intake manifold. NOTE: Seal the intake channels in intake manifold and in cylinder head using a clean rag. Continuation for all vehicles - Disconnect fuel injector connectors. Resistance of fuel injectors, checking - Test resistance of fuel injectors between terminals. Specified value: 13.0...19.0 Ohm NOTE: Resistance value is valid at approx. 20 degree C, At higher temperatures, resistance value increases. If specified value is not obtained: - Replace faulty fuel injector: Vehicles with engine code AFP, item 12, - Vehicles with engine code BDF, item 7. Note the following when installing the fuel injectors: - Replace O-rings on all fuel injectors and wet them slightly with clean motor oil. - Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips. - Position fuel distributor with secured fuel injectors and apply uniform pressure to press it in. - The connectors must audibly engage on valves when attached. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking voltage supply Vehicles with engine code AFP Page 1838 Fuse Block: Application and ID Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 3351 Continuation If the specified value is not obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the valid safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 36, display field 1 - Lambda probe voltage Lambda probe after catalyst Possible causes of malfunction if 02S sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) Page 2810 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 5877 - Remove positive bus securing bolt-1-on (+) positive terminal clamp. - Remove securing bolts -A- and remove cables to fuses. - Pull off connections -2-. - Relieve tension on fuse holder mounting in direction of -arrow A- and release clip with screwdriver in direction of -arrow B-. - Lift fuse holder from battery. - Remove screws -arrows- and remove cover -1-. Page 6159 Power Distribution Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 6505 7. Brake caliper - Servicing - Refer to Brakes and Traction Control; Servicing rear brakes (disc brakes) 8. Stub axle - Straightening operations are not allowed - Recutting the thread is not allowed! Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Lift vehicle. - Remove wheel. Relay Panel Locations Relay Box: Locations Relay Panel Locations Relay Panel Location The relay panel and 13-position auxiliary relay panel are located in the driver side footwell, behind the lower instrument panel trim. Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 6197 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. Page 5632 ^ Re-connect electrical connector for hydraulic pump motor. ^ Install ABS unit to bracket. Note: Hand-tighten bolts at first to make attaching the individual brake lines easier. ^ After tightening brake lines, tighten hydraulic unit. ^ Continue installation in reverse order of removal. ^ Bleed brake system ^ Enter radio code. ^ Code control module. Tightening Torques: Control module to hydraulic unit - maximum 4 Nm (35 inch lbs.) Hydraulic unit to bracket - 8 Nm (70 inch lbs.) Nut for brake master cylinder to brake booster - 20 Nm (15 ft. lbs.) Brake lines at ABS unit: Thread M10 x 1 - 14 Nm (10 ft. lbs.) Thread M12 x 1 - 14 Nm (10 ft. lbs.) Nut to body - 20 Nm (15 ft. lbs.) Cap nut to body - 20 Nm (15 ft. lbs.) Page 5238 Test table Page 5755 Lateral Accelerometer: Locations ESP-Sensor Unit (Vehicles With ESP) G419 - ESP-Sensor Unit (vehicles with ESP) Page 6376 Tie Rod: Service and Repair Tie rod, removing and installing Special tools and equipment ^ VAG 1332 Torque wrench ^ VAG 1332/5 Open jaw insert, 34 mm (1.34 in.) AF ^ VAG 1275 Pliers Removing NOTE: Tie rods can only be removed/installed with steering gear removed. - Seal line connections on power steering gear, if not already done. - Clean steering gear around boot. - Open clamps and push boot back. Page 5963 Starter Motor: Tools and Equipment Special tools and equipment - VAG1331 torque wrench (5 - 50 Nm) - VAG1332 torque wrench (40 - 200 Nm) Page 5274 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 626 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Page 4051 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 5-pin harness connector using to wiring diagram. Terminal -2- + socket 102 - Terminal -3- + socket 94 - Terminal -4- + socket 103 - Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring malfunction is detected and voltage was present between terminals -1- + -5-: - Replace Engine Control Module (ECM). Checking secondary winding Page 3003 Idle Speed: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 2820 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 4778 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 11 Alarm Module: Scan Tool Testing and Procedures Connecting VAS 5051 Special tools and equipment - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting All functions previously performed with the VAG 1551 or VAG 1552 can also be performed using the VAS 5051 tester via operating mode vehicle self-diagnosis. VAS 5051, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. Page 937 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Locations Electronic Power Control (EPC) Warning Lamp: Locations Electronic Power Control (EPC) Warning Lamp in instrument cluster Installation location of EPC warning lamp Significance of EPC warning lamp "EPC" is an abbreviation and stands for Electronic Power Control and means "electronic engine load control". If malfunctions are recognized in the EPC system during operation of the engine, the Engine Control Module (ECM) switches on the EPC warning lamp Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 4529 - Install support bar 10-222 A with legs 10-222 A/1 (6-cyl. engine adapter 10-222 A/3) and support engine/transmission in this position. - Remove bracket for power steering pressure hose. - Do not remove the bolts for the transmission carrier-arrows- until the transmission has been supported. - Remove pendulum support-arrows-. - Lower transmission approx. 60 mm -a-. - Pull black connector off sensor. - Remove bolt and pull sensor -1- out. - Replace seal. Installation is performed in the reverse order of removal. Tighten bolt to 10 Nm. Service and Repair Air Cleaner Housing: Service and Repair 1 - Harness connector Black, 2-pin - For Positive Crankcase Ventilation (PVC) heating element -N79- Check heater element voltage supply between terminals 1 and 2 with engine running: - Specified value: at least 11.5V 2 - Connecting hose For air circulation of fuel injectors 3 - Intake hose Note installation position 4 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-* Checking -G70-. Refer under "Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor", See: Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor/Testing and Inspection - Checking - G42-. Refer under "Powertrain Management/Computers and Control Systems/Air Temperature Sensor", See: Powertrain Management/Computers and Control Systems/Intake Air Temperature Sensor/Testing and Inspection - Sensor and harness connector terminals are gold plated 5 - Harness connector Black, 5 pin - Sensor and harness connector terminals are gold plated 6 - Seal Always replace if damaged 7 - Air cleaner upper section Locations After-Run Coolant Pump: Locations V51 - After-Run Coolant Pump - on cylinder head, left rear Page 826 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 4715 - Pry selector lever cable -3- off selector lever -2- with a screwdriver. - Pull circlip -1- for securing selector lever cable to selector lever housing out downward. - Pull selector cable carefully out of selector lever housing. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. - Remove solenoid securing bolts (Qty. 2). - With selector lever in position "1" remove solenoid with locking pin and spring from selector lever housing. Move selector lever back and forth slightly if necessary. - Loosen nut for selector lever mounting pin. Only counter-hold on mounting pin hex (mounting pin must not be turned). - Carefully drive mounting pin out with drift. - Remove selector. Installing Installation is performed in the reverse order of removal. Adjust selector lever cable. - Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Selector Mechanism Disassembling and Assembling Selector mechanism, disassembling and assembling Note: Lubricate mounting points and contact surfaces with grease Part No. G 052 142 A2. Page 3487 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Replacing Engine Control Module (ECM), Replacing Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Removing - First print out control module identification and thereby previous control module coding as follows: - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. The control unit identification and coding are indicated on the display, e.g.: 021906018B MOTRONIC ME7.1 G V06 -> Coding 00000 WSC 00000 - Print out control module identification by pressing scan tool PRINT button. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove wiper arms and plenum chamber cover. - Release harness connector from control module and disconnect. - Press retaining tab (arrow) to left and remove control module. Installing - Place new control module into retaining frame. - Install control module harness connector and lock. - Check previous coding and coding of new control module. - Adapt ECM to immobilizer. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Adapt new control module to throttle valve control module. - Activate cruise control system. - Check idle speed. - Generate readiness code. Page 4436 Part 1 Page 561 - Switch ignition off. NOTE: If the basic setting of the control module is interrupted, the cause could be one of the following: - Throttle valve cannot reach the mechanical stop because of contamination (e.g. oil deposits or an incorrectly adjusted accelerator pedal cable). - Battery voltage too low. - Throttle valve control module or wiring is faulty. Refer to "Throttle Valve Control Module, Checking", See: Electronic Throttle Control Module/Testing and Inspection After an interruption the fault "17973" is stored in DTC memory. When the ignition is switched on again, the basic setting is automatically performed again. - End basic setting by pressing -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 261 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 1398 Installing - Install crash sensor - 1 - with bolts - 3 - (6 Nm) and - 4 - (6 Nm). - Connect connector - 2 - into connector housing for crash sensor - 1 -. - Switch on ignition. - Close doors. CAUTION: Make sure no one is in vehicle. Page 4232 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4080 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 5500 ^ Remove seal using wedge 3409. Installing ^ Apply a thin coat of assembly lubricant G 052 150 A2 to piston and seal before inserting. ^ Place protective seal with outer sealing lip on the piston. ^ Hold piston in front of caliper housing and install inner sealing lip into groove in cylinder using wedge 3409. Page 6263 1. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 2. Suction hose 3. Pressure hose 4. Banjo bolt ^ 30 Nm (22 ft. lbs.) 5. Seal ^ Always replace 6. Suction hose ^ White or yellow ring must seat within retainer 7. Retainer 8. Hex nut 9. Mounting bracket Pressure line and suction hose (vehicles with A/C and 2.0 liter or VR6 engines) Page 3471 Engine Control Module: Locations J220 - Motronic Engine Control Module (ECM) J220 - Motronic Engine Control Module (ECM) - in plenum, center - for gasoline engine with motronic MFI Fuel Delivery, Checking Fuel Pressure: Testing and Inspection Fuel Delivery, Checking Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. With Generic Scan Tool Checking Fuel Delivery Test requirements - Voltage supply OK - VAG1348/3A remote control connected Test sequence - Remove fuel filler cap from fuel filler tube. - Disconnect supply line -3- (with white marking) and catch escaping fuel using a rag. NOTE: Depress buttons on hose connections to do so. WARNING: - The fuel or fuel lines in fuel system can become very hot (danger of scalding). - In addition, the fuel system is under pressure!Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection. - Wear protective goggles and protective gloves when working on the fuel system. - Connect pressure gauge (VAG1318) to fuel supply line using adapters (VAG1318/23 and VAG1318/17). - Connect hose adapter (VAG1318/16) to adapter (VAG1318/11) of pressure gauge and hold into measuring container. - Open shut-off valve of pressure gauge. Lever will point in direction of flow -A-. Page 539 Page 1967 Camshaft: Tools and Equipment Camshaft Alignment Tool - AST Tool # 3243 Camshaft Alignment Tool AST tool# 3243 Used to hold camshafts at T.D.C. position. Applicable to VW and Audi 2.8L V-6 engines with two valves per cylinder. Used in conjunction with 3242. - Used to Hold the Camshafts at T.D.C. Position - Applicable to 2.8L V-6 VW and Audi Models - Used in conjunction with #3242 Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 4526 Driving in - Drive in spring pins until flush after inserting selector shaft, engaging lever and detent segment. Fig. 2 Removing and installing selector shaft with selector segments Note: With valve body installed do not damage the conductor strip. - Remove selector segment spring -A-. - Remove screw with washer (arrow). The washer prevents selector shaft movement. Fig. 3 Inserting guide plate and supporting plate Fig. 4 Inserting pawl with return spring Service and Repair Air Cleaner Housing: Service and Repair 1 - Harness connector Black, 2-pin - For Positive Crankcase Ventilation (PVC) heating element -N79- Check heater element voltage supply between terminals 1 and 2 with engine running: - Specified value: at least 11.5V 2 - Connecting hose For air circulation of fuel injectors 3 - Intake hose Note installation position 4 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-* Checking -G70-. Refer under "Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor", See: Computers and Control Systems/Air Flow Meter/Sensor/Testing and Inspection - Checking - G42-. Refer under "Powertrain Management/Computers and Control Systems/Air Temperature Sensor", See: Computers and Control Systems/Intake Air Temperature Sensor/Testing and Inspection - Sensor and harness connector terminals are gold plated 5 - Harness connector Black, 5 pin - Sensor and harness connector terminals are gold plated 6 - Seal Always replace if damaged 7 - Air cleaner upper section Page 3001 Explanation of 8 digit number block If the specified value is obtained: - Briefly increase engine speed (rev- up) and allow engine to run at idle for 2 minutes. Checking idle speed - Change to display group 056 as follows: - Press -C- button. - Press buttons -0-, -5- and -6- to input display group number 56 (056) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 56 -> 1234 - Check actual idle speed in display field 1. - Check specified idle speed in display field 2. - Check operating mode in display field 4. Explanation of 5 digit number block Page 1623 3428 - New TDI Cam Lock Bar Page 3374 - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -3-, and -4- to input display group number 34 (034) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 34 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by the Engine Control Module (ECM). - Check specified values in display fields 1-4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Bonded Rubber Bushings, Removing and Installing Axle Beam: Service and Repair Bonded Rubber Bushings, Removing and Installing Special tools and equipment ^ 3301 Assembly tool ^ 3346 Assembly tool ^ 3416/1 Press piece ^ 3416/2 Press Piece ^ 3416/3 Support tube Removing. Recall 04V096000: Brake Light Switch Malfunction Brake Light Switch: All Technical Service Bulletins Recall 04V096000: Brake Light Switch Malfunction DEFECT: The brake light switch on these vehicles may malfunction. If this happens, the brake lights could become inoperative, or come on and stay on, even though the vehicle is parked. REMEDY: Dealers will replace these switches. The manufacturer has reported that owner notification is expected to begin during April 2004. Owners may contact Volkswagen at 1-800-822-8987. Page 267 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 5589 <-- Remove brake lines -3- on the side of hydraulic unit CAUTION! DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC CAUTION! MAKE SURE NO BRAKE FLUID <-- From the repair kit provided (1J0 998 375) place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates Note: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION! DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT Page 167 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5045 1. Selector lever knob - Screw on and off together with gaiter 2. Boot - Separating from gear shift knob = Fig. 1 - Connect to gear shift knob before installing = Fig. 1 - Remove and install together with gear shift knob 3. Sleeve 4. Clamp - To secure gear shift knob on gear lever 5. Frame 6. Sound insulation Specifications Idle Speed: Specifications Not adjustable 680 to 720 rpm Page 4477 Fill Plug: Locations 5 Speed 09A Transmission 5 Speed 09A Transmission Level Plug (with Overflow Line Tube)................................................................................................... ................................................................. 15 Nm Fill Plug (with protective cap) Note: Always replace cap. The cap secures the sealing plug. Page 1225 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 2899 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1817 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 567 Engine Control Module: Tools and Equipment Wire Terminal Extractor AST tool# H 4673-9 Page 6429 1. Self-locking nut ^ 60 Nm (44 ft. lbs.) ^ Always replace 2. Stop 3. Suspension strut turret 4. Nut ^ 60 Nm (44 ft. lbs.) 5. Suspension strut mount 6. Axial ball bearing 7. Spring plate ^ Only on vehicles with heavy duty suspension (P/N 1GB) ^ This P/N if relevant is entered on vehicle data label in luggage compartment or Service booklet 8. Coil spring ^ Observe color code ^ Outer surface of spring must not be damaged 9. Self-locking nut ^ 60 Nm (44 ft. lbs.) & turn 90° further ^ Never turn less than 90° ^ Always replace ^ Turning angle tolerance 90° to 120° 10. Wheel bearing housing 11. Bolt ^ Always replace 12. Shock absorber Page 3037 Continuation If the display does not change: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box sockets 40 + 41 and air conditioner system using wiring diagram. Wire resistance: max. 1.5 ohms If no malfunction can be found in the wiring: - Check function of air conditioner control module. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 1340 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 3166 - Slowly depress accelerator pedal up to Wide Open Throttle (WOT) stop while observing the percentage display. The percentage display must increase uniformly. - Check specified value of throttle valve position (absolute) at Wide Open Throttle (WOT) stop: - End diagnosis and switch ignition off. If specified values are not obtained: - Disconnect the 6-pin connector at the throttle valve control module (arrow). Check resistance - Measure resistance of Throttle drive (power accelerator actuation) -G186- in Throttle Valve Control Module -J338- between terminals 3 + 5 Specified value: 1.0...5.0 Ohm If specified value is not obtained: - Replace Throttle Valve Control Module -J338-: Page 1940 - Measure resistance between terminals of the respective valve for camshaft adjustment. Specified value: 10...18 Ohms If specified value is not obtained: - Replace control housing for camshaft adjustment, item3. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit according to wiring diagram Wire resistance: max: 1.5 Ohms If resistances and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2748 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 1291 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 643 Test Step 10 - 11 Page 4756 - Without damaging turbine shaft, carefully pry up split sleeve bearing using a screwdriver. - Remove filings and sticky tape. - Replace torque converter seal. Page 5990 Fuse arrangements in fuse bracket/battery S162 - Fuse -1- (30) In Fuse Bracket/Battery Page 1044 - Prior to Installation, pull out brake switch plunger (black arrow) to full extension. - Apply a light coat of lubricant Part No. G 052 142 A2 to end of plunger (black arrow). Lubricant is considered shop supply. - Keep brake pedal in the up position (IMPORTANT! hold pedal up if necessary while installing switch). - Push switch in and seat fully into opening (pressing plunger against pedal to adjust). - Once seated, secure switch by turning it to the right approx. 45° (must be turned fully to it's stop! see magnified views below). ^ This action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate as well as locks in plunger (arrow) adjustment. Once installed, inspect internal stop pin of switch (inset) for correct positioning (see examples below). CAUTION! When installing, the switch must be rotated until it is fully locked and electrical connector is in the horizontal position. Page 258 Page 4237 Part 2 Page 240 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Diagram Information and Instructions Heated Glass Element Switch: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5251 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Page 3671 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (6 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (6 spd. Manual transmission) Page 4683 Shift Interlock Cable: Service and Repair 5 Speed Automatic 09A, Locking Cable Remove & Install Removing Installation position of locking cable 1. Footwell vents 2. Support/instrument panel 3. Heater unit heck whether a coded radio is fitted. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Remove driver's airbag and steering wheel. - Remove left trim under instrument panel. - Remove steering column trim. - Remove handle for steering column height and reach adjustment. - Turn ignition key to "ignition on" position. - Shift selector lever into "P" position. Page 3623 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 6- pin harness connector for open circuit according to wiring diagram. Terminal -4- + socket 5: Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 6-pin harness connector terminal -3- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms Aging Check Oxygen Sensor 1 Aging, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1788/10 engine speed adjuster Test conditions - Coolant temperature at least 85 °C display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 5584 An initial quantity of required replacement parts (other than brake fluid) calculated according to vehicles located in your area will be shipped to you prior to the owner notification mailings. The parts are as shown. Additional required parts after depletion of the initial shipment must be ordered by you from your facing parts depot and not to exceed 50% of the vehicles left for repair according to your area vehicle allocation list. Please note: Excess parts ordered by you will either be denied shipment or requested to be returned. Parts Return All removed control units must be properly tagged with dealer number, repair order number and VIN, and immediately returned in the box of the new unit to: Volkswagen c/o 1601 Clay St. Detroit, MI 48211 ATTENTION: (Recall - WJ) Time Requirements Reimbursement To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below. Claims will only be paid for vehicles that show the WJ code in the OTIS campaign inquiry system on the day of repair. A copy of the print out must be attached and remain with your copy of the repair code. WJ Data Entry Procedure The system automatically enters the part number and labor applicable to the above listed codes. Page 2592 Catalytic Converter: Testing and Inspection With Generic Scan Tool Three Way Catalytic Converter (TWC), Checking Function test - Select the measuring value "Test-ID 01: Catalytic converter" and check whether the specified values are being reached, Diagnostic mode 6: Check test results of components that are not continuously monitored. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 6: Check Test of Parts Not Constantly Monitored - End diagnosis and switch ignition off. If the specified values are exceeded: - Replace the front exhaust pipe with catalytic converter: Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 14. Continuation for all vehicles - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5978 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4639 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2159 Intake Manifold: Vacuum and Vapor Hose Diagrams Evaporative emissions system, diagram Component Overview 1 - Fuel filler door module 2 - Fuel tank 3 - Fuel delivery module 4 - Upper intake manifold 5 - Pressure regulator 6 - Supply rail with injectors 7 - Fuel filter Install position: arrow indicates direction of flow 8 - Solenoid valve 1 for charcoal canister (N80) In the engine compartment on the right Install position: arrow indicates the direction of flow - Check via Output DTM: - Checking operation 9 - Test socket 10 - Gravity/overflow - valve 11 - Pressure retention valve Page 262 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 3988 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 6452 - Remove brake carrier with brake caliper. To do this remove brake caliper and hang up with wire or similar. - Mark installation position of bolts from ball joint to control arm. - Remove bolts - arrows - . - Press axle shaft out. Note: When pressing axle shaft out ensure sufficient clearance is available. - Pull wheel bearing housing with ball joint out from control arm. - Remove axle shaft from wheel bearing housing and tie up. - The axle shaft must not hang down! - The inner CV joint will be damaged through overflexing. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove cover plate. - Remove connecting link from control arm. - Release speed sensor wiring from suspension strut. Caution: Place engine/transmission jack V.A.G. 1383/A underneath (danger of accident from falling parts when removing the wheel hub and the wheel bearing). Pulling out wheel hub - Insert thrust bolts -1 - in wheel bearing housing. - Install support - 2 - piston cylinder - 3 - with pull rod and special nut - 4 - . - Hold tool firmly pull out wheel hub. Page 5518 ^ Press piston back. ^ Insert brake pad with retaining spring in brake caliper housing. Directional brake pads Directional brake pads are installed on some vehicles. The inside brake pad (next to caliper piston) is colored white on the backside. The outside brake pad (with 3-fingered clip) has a black coloring on the backside. Install brake caliper housing with brake pads to wheel bearing housing. Notes: ^ Locate lower brake caliper housing (arrow) first. ^ The brake caliper housing tab (arrow) must be behind the wheel bearing housing guide. ^ Secure brake caliper housing to wheel bearing housing with guide pins and torque to 28 Nm (21 ft. lbs.). Notes: ^ After replacing the brake pads, depress the brake pedal firmly several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position. ^ After replacing the brake pads, check the brake fluid level in the fluid reservoir. FN 3 Brake Caliper, Servicing Brake pads, removing and installing Special tools and equipment required Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 4833 1. Plug - Always replace seal see Fig. 2 - Checking ATF level and topping up 2. Overflow pipe - Remove to drain ATF see Fig. 1 - Screw in onto stop - Checking ATF level and topping up 3. Oil pan 4. Bolt, 12 Nm 5. Magnet - Insert in the recess in oil pan 6. Spacer bushing - Press into gasket 7. Gasket - Always replace - Press spacer bushings into gasket 8. ATF screen - Installing see Fig. 10 9. Bolt, 5 Nm - Tighten the two centering bolts (arrow) first by hand 10. Gasket - Always replace - Insert in valve body 11. Valve body - Removing see Fig. 4 - Installing see Fig. 9 Page 5399 <-- Remove clamp -3- and disconnect intake air hose from mass air flow sensor <-- If applicable, remove secondary air hose -4- from air filter box -5<-- Remove screws -6- securing air filter box and remove air filter box ^ If applicable, remove and move aside secondary air relay box and harness from supporting clip ^ If applicable, disconnect electrical connector on brake fluid reservoir <-- Release ABS control module electrical connector by pulling latch upward -arrow 1<-- Pull electrical connector off ABS control module -arrow 2^ Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws ^ Lower vehicle ^ Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle ^ Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor ^ Raise vehicle ^ Close left front and left rear caliper bleed screws when brake fluid stops flowing ^ Lower vehicle ^ Do not remove brake pedal depressor from brake pedal at this time Note: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system ^ Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 3117 Continuation for all vehicles - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 5781 ^ Secure wheel speed sensor wire (arrows). Note: Do not twist wires in the wheel well. ^ Cut 2-pin connector at new speed sensor wire (if installed) using stripping pliers from repair kit. ^ Strip 15 mm (5/8 inch) insulation off wire end and fold over stripped wire. ^ Connect wheel speed sensor wire using correct connector from wiring repair kit VAS 1978. Page 1819 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5358 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 1499 Part 2 Page 4780 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 2000 Crankshaft Main Bearing: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 3831 - Operate remote control. Slowly close shut-off valve until on pressure gauge 3 bar is indicated. Do not change position of shut-off valve any more. - Empty measuring container. - Delivery rate of Fuel Pump (FP) is dependent on battery voltage. Therefore, connect multimeter to vehicle battery using adapter cables. - Operate remote control 30 seconds long and measure battery voltage. - Compare fuel quantity pumped with specified value. *) Minimum delivery rate cu.cm/30 s **) Voltage at fuel pump with engine off and pump running (approx. 2 volts less than battery voltage). Read-out example: During test, a voltage of 12.2 volts is measured at battery. Since the voltage at the pump is approx. 2 volts less than battery voltage, there is a minimum delivery rate of 200 cu.cm/30 s. If minimum delivery rate is not obtained: - Check fuel lines for possible restrictions (kinks) or clogging. - Disconnect supply line -1- from fuel filter input. NOTE: Depress buttons on hose connections to do so. - Connect pressure gauge (VAG1318) with adapter (1318/17) to hose. - Repeat test of delivery quantity. If minimum delivery rate is obtained now: - Replace fuel filter. If minimum delivery rate is still not obtained: - Remove Fuel Pump (FP) unit and check filter strainer for dirt. Only if no malfunctions have been found yet: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): Specifications Flex Plate: Specifications FLEX PLATE TORQUE Torque ................................................................................................................................................. .................... 60 Nm. (44 ft. lbs.) + 90° (1/4 turn) [1] [1] Install new bolts. Page 4269 ^ The tester requests you to switch the ignition OFF. - Switch ignition OFF. ^ The tester requests you to switch the ignition ON. - Switch ignition ON when prompted. After switching ignition ON, the ECM has been re-initialized, however, fault memories must now be erased. - Select the "Continue button" Fault memories, erasing after "Update - Programming" (flashing) Due to the CAN bus system, fault messages will be stored in various Control Modules during programming. To erase ALL fault memories: - Confirm by selecting the right arrow --> button. Once fault memories have been erased: ^ Similar screen appears. ^ Old ECM Part No. and software level still appear at (arrow). ^ Function ended appears at bottom of screen. - Finish update of the ECM by selecting the left arrow <-- button. ^ Similar screen appears. Page 4704 - With selector lever in position "1" remove solenoid with locking pin and spring from the selector lever housing. Move selector lever back and forth slightly if necessary. Installing Installation is performed in the reverse order of removal. Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Page 1944 Compression Check: Testing and Inspection Compression pressure, checking Special tools, equipment, test and inspection devices; required accessories 3122 B Spark plug removal tool - T10029 Spark plug connector tool - VAG 1331 Torque wrench (5-50 Nm) - VAG 1763 Compression tester Test condition - Engine oil temperature must be at least 30°C. - Battery voltage must be at least 11.5 V. Test procedure - Disconnect connector from heating resistor (N79) and remove intake hose between upper half of air filter and throttle control unit (J338) together with crankcase purge valve. - Use assembly tool T10029 to remove spark plug connector and ignition lines. - Remove engine cover. - Remove spark plugs with spark plug tool 3122 B. Page 1839 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 786 Front wheel speed sensor wiring, removing and installing Required special tools and equipment ^ VAS 1978 wiring repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery. ^ Remove Mass Air Flow (MAF) sensor connector -1- from air filter duct. ^ Remove bolts -2- at air filter -3- and place filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. - Release connector from control module (arrow -1-) and pull off (arrow -2-) Page 5565 ^ Screw piston into housing by turning knurled wheel clockwise. Notes: ^ Install special tool 3272 with the collar (arrow) seated on the brake caliper. ^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow -A-) provided for this purpose. ^ If the piston is pushed back with a piston re-seeing tool or by operating the foot brake, the automatic adjustment in the brake caliper is destroyed. ^ Install brake pads. Pre-bleeding brake caliper ^ Position brake caliper as shown in illustration. ^ Open bleeder valve (arrow -A-) and fill a standard bleeder bottle with brake fluid until bubble-free brake fluid flows from brake hose connection (arrow-B-). ^ Close bleeder valve. Page 4043 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 2373 ALWAYS perform complete repair as outlined in this Technical Bulletin. DO NOT skip steps or fail to replace parts as instructed. Parts required: See Required Parts and Tools. Wiring repair, general procedures 1. Review instruction manual included in VAS 1978 wiring repair kit. 2. ONLY use parts included in this kit. if supplemental wiring terminals or supplies are required, use only materials from the VAS 1978 kit. Wiring, making splice connections 1. All wiring splice connections MUST be made using the VAS 1978/1 crimping tool with either the VAS 1978/24 crimp tool die for connections using (light yellow) crimp connector Part No: 111971941 A, or the VAS 1978/2 crimp tool die for connections that utilize other crimp connectors. 2. All wiring splice connections MUST be heat shrunk and sealed using the hot air blower from the VAS 1978 kit and the VAS 1978/15 adapter. 3. When required, strip wiring ends using the VAS 1978/3 wire stripper (this minimizes possibility of broken wire strands). Unused wiring, taping back to harness During this repair, ALL unused wires in the vehicle must be terminated using a cut, stretch, fold, and tape technique as follows: This prevents unused wires from coming in contact with ground or any other circuit. ^ Cut wires with suitable wire cutters. ^ Stretch (pull) wire insulation with pliers to extend slightly beyond end of wire strands. ^ Fold wire over upon itself. ^ Tape wire using vinyl tape. Wiring terminals and seals, removing and installing in connectors 1. Removal of terminals from 10 or 14 pin engine harness connector or fuel pump connector (if needed) must be performed using the VAS 1978/4a. 2. Insertion of the single wire seals on 10 or 14 pin engine harness connector or fuel pump connector (if needed) must be performed using the appropriate seal tool from VAS 1978 kit. Vehicle, Preparation The following should be performed prior to installation of the repair kit. ^ Obtain radio code, odometer adaptation readings. ^ Disconnect battery Ground (GND) cable. ^ For MY 2001 vehicles, remove battery (see Repair Manual, Group 27). ^ Remove windshield washer reservoir. ^ Loosen fuel and evaporative emission tube housing from strut tower. ^ Remove windshield wipers and plenum cover (see Repair Manual, Group 92). ^ Cut and remove three tie wraps holding engine harness to firewall in plenum. ^ Remove wiring harness (cable) channel cover on left side of engine compartment (see Repair Manual, Group 97). ^ Disconnect 10 Pin (MY 1999 vehicles) or 14 pin (MY 2000 vehicles) connector in wiring harness channel (MY 2001 vehicles below battery). ^ Remove instrument panel (see Repair Manual, Group 70). Page 3702 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4413 Test Sep 7 - 9 Brakes - Master Cylinder/ABS Pressure Testing Adapter Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - Master Cylinder/ABS Pressure Testing Adapter Condition Master Cylinder / ABS, Adaptor for Checking Pressure Pressure adaptor VAG 1310/26 allows the use of VAG 1310 A to check for hydraulic pressure loss at either the master cylinder or ABS control unit. Before replacing the ABS unit due to an incorrect pressure reading when performing Leak Test, check brake fluid pressure at the master cylinder and ABS unit as follows: 47 06 01 Aug. 28, 2006 2002320 Supersedes T.B. Group 47 number 01-01 dated January 4, 2001 due to updated information. Technical Background Introduction of adaptor to allow pressure testing of brake hydraulic system. Production Solution No production change required. Service Pressure Leak Test Obtain special tools: - VAG 1310/26 Pressure Adaptor - VAG 1310 A Brake Pressure Gauge Use VAG 1310/26 with VAG 1310 A to measure hydraulic brake pressure at master cylinder and ABS unit as follows: - Remove brake lines at either master cylinder port (A or B). Install VAG 1310/26 at port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". Brake fluid pressure can also be checked at the ABS unit: - Disconnect brake lines from ABS unit to disc brake calipers (1-4), one at a time. Page 5275 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Page 3322 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 4620 - Install sound insulation tray. Tightening torques Flanged shaft to transmission 25 Nm (conical head bolt) Drive shaft to flanged shaft: Refer to Drive Axles, Bearings and Joints. Selector Shaft Seal, Replacing Selector shaft seal, replacing Special tools and equipment - T10090 Thrust piece - V.A.G 1331 Torque wrench - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Remove lever -1- from selector shaft. - Disconnect multi-function switch connector -2-. - Remove multi-function switch (F125) -3-. Page 6139 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 1711 - Place drip tray under transmission. - Bring ATF to test temperature. Test temperature: 35°C to 45°C - Remove ATF inspection plug from transmission housing (arrow). At first the ATF present in the overflow pipe (arrow 2) will run out. - Observe amount of ATF draining from plug hole afterward. If ATF continues to drip out of hole: ATF need not be topped up. - Install new seal (arrow 1) to ATF inspection plug and tighten to 15 Nm. ATF check is completed. - End output with V.A.G 1551. See below. If the ATF present in the overflow pipe runs out of the plug hole but no further draining is observed: Top up ATF in transmission. ATF, Topping Up With engine running. WARNING: When working in the vicinity of the radiator, always maintain a safe working distance - Danger of injury! - Fan could start automatically. Page 1705 Indicated on display 1) appears alternately - Start engine. - Press key 1 for "Rapid data transfer" mode. Indicated on display Press keys O and 2 to select address word "Transmission electronics". Indicated on display Confirm entry with key Q. Indicated on display Press keys O and 8 to select function "Read measured value block". Indicated on display Confirm entry with key Q. Locations Page 4685 - Guide cable in between heater -3- and footwell vent -1- behind support/ instrument. - Shift selector lever into "P" position. - Pull out cable slightly from cable sheath and engage in locking lever-arrow B-. - Engage cable support bracket in selector lever bracket. - Insert locking cable into steering lock. - Flattened side of locking cable faces downward during insertion. - Press on clip -2- of locking cable -3-. Installation position: Push on clip from above. Angled ends of clip face steering lock. Ensure that clip is properly located. - Adjust locking cable. - Check operation of ignition key withdrawal lock. Page 6439 Suspension Strut / Shock Absorber: Tools and Equipment VW/Audi Front Shock Socket AST tool# 3078 22mm socket used to torque front shock absorber nuts. After-market struts may have a 21mm nut. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 2393 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation High Pressure Sensor G65 High Pressure Sensor G65 Where applicable, High Pressure Sensor G65 transmits a square wave signal to Coolant Fan Control (FC) Control Module J293 at a rate which varies according to the refrigerant system pressure. J293 reacts to the pulse rate of the signal from G65 as follows: If the refrigerant system pressure rises, J293 switches the radiator fan(s) to the second speed. - Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), Coolant Fan Control (FC) Control Module J293 switches the A/C Clutch N25. - On Climatronic equipped models it informs the A/C Display Control Head E87 that the pressure in the refrigerant system is OK and that A/C Clutch N25 can be switched on via J293). On applicable engines, the signal generated by G65 is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance. Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Page 5501 ^ Screw piston into housing by turning knurled wheel clockwise. Notes: ^ Install special tool 3272 with the collar (arrow) seated on the brake caliper. ^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow -A-) provided for this purpose. ^ If the piston is pushed back with a piston re-seeing tool or by operating the foot brake, the automatic adjustment in the brake caliper is destroyed. ^ Install brake pads. Pre-bleeding brake caliper ^ Position brake caliper as shown in illustration. ^ Open bleeder valve (arrow -A-) and fill a standard bleeder bottle with brake fluid until bubble-free brake fluid flows from brake hose connection (arrow-B-). ^ Close bleeder valve. Page 5158 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 2779 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 4, display field 3 - Coolant temperature Display Group 4, Display Field 3 Continuation of check when display approx. -40 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 4719 Shifter A/T: Service and Repair 5 Speed Automatic 09A Servicing Selector mechanism, servicing Special tools and equipment - V.A.G 1331 Torque wrench - 8852 A Adjustment gauge for locking cable WARNING: Before working on the when it is running, move file selector lever into position "P" and apply the parking brake. Selector mechanism, checking Note: - It should not be possible to operate the starter while the selector lever is in position "2" "3' "4" "D" or "R". - When traveling at speeds above 5 km/h and shifting into selector lever position "N' the shift lock solenoid must not engage and block the selector lever. The selector lever can be shifted into a driving gear. - When traveling below 5 km/h (almost stopped) and shifting into selector lever position "N' the shift lock solenoid must not engage until after approx. 1 sec. The selector lever cannot be shifted out of "N" position until the brake pedal is depressed. Selector lever in "P" position and ignition switched on: Brake pedal not depressed: Selector lever is locked and cannot be shifted out of "P" position. Shift lock solenoid blocks selector lever. - Brake pedal depressed: Shift lock solenoid releases selector lever. It is possible to shift into a driving gear. Shift selector lever slowly from "P" position through "R", "N", "D", "4", "3" and "2" and check whether the display in the instrument cluster shows the correct selector lever position in each case. Selector lever in "N" position and ignition switched on: Brake pedal not depressed: Selector lever is locked and cannot be shifted out of "N" position. Shift lock solenoid blocks selector lever. - Brake pedal depressed: Shift lock solenoid releases selector lever. It is possible to shift into a driving gear. Selector lever in "D" position, ignition and lights switched on: Shift selector lever into Tiptronic gate. The illumination of the "D" symbol in the selector lever display should go out, and the "+" and "-" symbols should light up. The selector lever position display in the instrument cluster must change from "PRND432" to "54321" when the selector lever is moved into the Tiptronic gate. Page 3606 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 4-pin harness connector -1- to Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130-. Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -1- and -2(harness connector to Engine Control Module (ECM)). - Start engine and run at idle - Measure voltage supply and observe display group 41, display field 4. Display: Htg.aC.ON - Specified value: 11.0-14.5 V Display: Htg.aC.ON/Htg.aC.OFF (alternating) - Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Diagram Information and Instructions Shift Interlock Solenoid: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 6032 Page 5994 S179 - Fuse -7- (30) in fuse bracket/battery S180 - Fuse -8- (30) In Fuse Bracket/Battery S180 - Fuse -8- (30) in fuse bracket/battery Locations Power Seat Control Module: Locations J136 - Memory Seat Control Module - on bottom of driver's seat, left side Page 3772 Production Solution No production change required. Service Tip: Oil level MUST be correct, if overfilled, level should be adjusted to the proper level prior to performing procedure. Adjusting oil level is NOT covered by Warranty. Exhaust system damage from outside influences is NOT covered by Warranty. The following steps are to be followed before replacement of catalytic converters. Inspect complete exhaust system for broken or missing components, loose clamps, etc. Repair as necessary. If vehicle has MIL ON, investigate fault memory without erasing codes. Before performing any repair, make a print out of fault memory including: Address 01 fault memory (including ECM information) Address 01 Measuring Value Block 46 (and 47, if applicable) Tip: For 4 bank systems such as Phaeton W12, Display groups 46 and 47 must be printed out from addresses 01 and 11. OBD freeze-frame mode 2, and 6. Tip: For OBD, see Repair Manual - Fuel Injection & Ignition 2.0 Liter 4yl. 2V Generic Scan Tool Engine Code(s). AEG, BBW, BEV, ST-Generic Scan Tool Steps for printing OBD from the touch screen: Select "OBD". Select "mode 2". Select all PIDS displayed (use scroll bar if necessary). Select right arrow key to display results. Select "print", and then save result. Save results for modes 2 and 6. Print - self diagnosis log. DO NOT replace catalyst if software updates related to catalyst are available. Check for applicable Technical Bulletins or Campaigns. Perform any applicable software updates available through Technical Bulletins or Campaigns. If other faults related to fuel mixture, oxygen sensor or misfire are present: DO NOT replace catalyst(s). Correct condition, erase DTCs, reset readiness codes and monitor measured value block (MVB) in 46, 47 until complete ("Test OK or Test n OK"). If after repair of other faults, diagnostic result in MVB 46 (and 47, if applicable) is/are OK: DO NOT replace catalyst(s). Page 3750 Air Injection Control Valve: Service and Repair Combination valve, removing and installing Special tools, equipment, test and inspection devices; required accessories - VAG 1331 torque wrench (5 - 50 Nm) or equivalent Removing Note: The battery ground strap must eventually be disconnected in the further course of work. Check whether the vehicle has a coded radio system. It may be necessary to disable the theft-deterrent feature by entering the appropriate code. - With ignition off, disconnect battery. - Remove damping pans. - Put lock carrier into service position. Vehicles with air conditioning - Remove poly V-belt. - Remove air conditioning compressor - Remove refrigerant line retention strap(s). CAUTION: The A/C refrigerant circuit must not be opened! Notes: The refrigerant circuit may only be opened in workshops which have both the trained personnel and the proper tools and equipment. - To prevent damage to the condenser and the refrigerant fines1hoses, be careful that the lines and hoses are not overextended, creased, or bent. Procedure for all vehicles - Remove discharge hose on combination valve between combination valve and air pump. - Remove vacuum hose on combination valve. - Remove combination valve from bottom of intake manifold and pull it out along with connection nozzles. Install Installation is in reverse sequence. Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1581 - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Vehicles with engine code BDF - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. Page 2004 Crankshaft: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 3565 - Perform resistance measurement on Intake Air Temperature (IAT) sensor -G42-, terminals -1(signal) and 3 (Ground (GND)). Scale -A- shows resistance values for temperature range 0-50 °C and scale -B- shows the values for temperature range 50-100 °C. Examples: - 30 °C is in range -A- and corresponds to a resistance of 1.5-2.0 Kohms - 80 °C is in range -B- and corresponds to a resistance of 275-375 Kohms If the specified value is not obtained: - Replace Mass Air Flow (MAF) sensor -G70-, item -24-. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Instruments - Various Instrument Cluster Malfunctions Coolant Reservoir: Customer Interest Instruments - Various Instrument Cluster Malfunctions 97 07 03 May 3, 2007 2002270, Supersedes Technical Bulletin Group 97 number 01-01 dated April 30, 2001 due to inclusion into ElsaWeb. Condition Vehicle Information Wiring Harness, Coolant Contamination at Instrument Cluster Contamination can result in various malfunctions of the instrument cluster. Technical Background Coolant leaking from coolant reservoir bottle wiring connector contaminates the wiring harness. Production Solution Improved coolant reservoir bottle. Service If an instrument cluster exhibits a malfunction: ^ Record Vehicle Mileage (odometer adaptation reading) (see Repair Manual). ^ Print out any and all instrument cluster coding and adaptation values using the VAS 5051/5052 for use after repairs are complete. ^ Remove instrument cluster (see Repair Manual). ^ Remove blue flat contact housing cover and inspect wire terminals for moisture or corrosion. If moisture or corrosion is found (arrow): ^ Repair wiring using repair kit 1JM998001. This kit contains overlay harnesses, splice connectors, tape and installation tube necessary to repair the affected harnesses. The instrument cluster, coolant bottle and fuel pump/fuel sender must also be replaced. IMPORTANT! Page 2148 Engine Oil Pressure: Testing and Inspection Oil pressure and oil pressure switch, checking Special tools, equipment, test and inspection devices; required accessories - VAG 1342 Oil pressure tester - VAG 1527 B Diode test lamp - VAG 1594 A Supplemental measuring tool set Function of the Dynamic Oil Pressure Warning System The oil pressure switch is open without pressure and is closed when the operating pressure is reached. The oil pressure warning is actuated approx. 10 seconds after the ignition is turned on. Oil pressure warning turn-on delay: approx. 3 seconds. Oil pressure warning turn-off delay: approx. 5 seconds. Checking the indicator light for operation with oil pressure After the ignition is turned on, the indicator light (K3) in the instrument panel must light for approx. 3 seconds and then extinguish. The test ends when the engine starts running. Warning criteria Warning is provided both visually (blinking indicator light) and acoustically (buzzer sounds three times). This occurs under the following operational Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) switch Page 3774 Warranty Required Parts and Tools When replacing any catalyst, your VIN may be required to ensure the correct part is ordered (check with your parts department). No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2135 - Cut tubular nozzle off at front mark (nozzle diameter approx. 3 mm). - Apply sealing compound to cleaned sealing surface, as shown. The bead must: be 2 - 3 mm thick - run past the inside around the bores -arrowsNote: If the bead is too thick, excess sealing compound can get in the oil pan and clog the strainer in the pump suction line. - Apply sealing compound to the clean surface as shown. - Immediately put oil pan in place and insert all bolts, leaving them loose. - Tighten bolts to 15 Nm. - Tighten oil pan to gear bolts to 45 Nm. Note: After assembling the oil pan, wait approximately 30 minutes for the sealing compound to dry before filling with oil. Complete assembly in reverse order. 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module: Locations 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module location The control module is located in plenum chamber. Page 5100 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 273 Owner Letter Description and Operation Coolant Temperature Sensor / Switch HVAC: Description and Operation A/C cut-out thermal switch -F163- (Item # 9 in image) - Switches off A/C clutch -N25- at excessively high coolant temperatures. - Off at 119 °C (246 °F) - On at 112 °C (234 °F). Page 5534 Remove wheels and separate brake calipers from carrier as outlined in Repair Manual Group 44 Wheels, Tires, Vehicle Alignment and Group 46 - Brakes - Mechanical components in ElsaWeb. Brake Disc Inspection A detailed brake disc inspection is needed to determine if the brake disc should be machined or replaced. Inspect brake disc friction surfaces on both sides of the brake disc for: ^ Severe discoloration (bluing) ^ High heat surface damage (raised hard spots) ^ Visible cracks Brake discs showing any of the above described conditions MUST be replaced. Disc Thickness Measuring Each brake disc has the minimum allowed thickness cast, stamped or laser-etched into the disc hub. ^ Measure the brake disc thickness in 4 locations using either the Pro Cut International(TM) disc thickness measuring tool Part No. 50-902 or the Hunter Engineering Company disc thickness measuring tool Part No. 25-99-2. Measurements MUST be taken the same distance from the brake disc outer circumference to ensure consistency. Note Brake Disc Machining Tip: Page 825 If indication remains at approx. -40 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Continuation of test if indication is approx. 140 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles If indication jumps to approx. -40 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, - Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If indication remains at approx. 140 degree C: - End diagnosis and switch ignition off. - Check wires according to wiring diagram. Checking wiring - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 1765 SW-Wu Page 4025 Continuation for all vehicles - Measure resistance between terminals of solenoid valve. Specified value: 25.0...35.0 Ohm If specified value is not obtained: - Replace Intake Manifold Change-Over Valve -N156-: Vehicles with engine code AFP, item 40, - Vehicles with engine code BDF, item 2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with engine code AFP - Check wire between test box socket 104+2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with engine code BDF Description and Operation Electronic Throttle Control Module: Description and Operation Function of the Electronic Throttle Control System In the electronic throttle control system, the throttle valve is not actuated by a cable from the accelerator. There is no mechanical connection between the accelerator and throttle valve. The accelerator position is communicated to the engine control module by two throttle position sensors (variable resistance, accommodated in a casing), which are connected to the accelerator. The accelerator position (determined by the driver) is a main input variable for the engine control module. An electric motor (throttle actuator) in the throttle valve control module -J338- actuates the throttle valve over the entire range of engine speeds and load. The throttle valve is actuated by the throttle actuator under instructions from the engine control module. When the engine is off and the ignition is turned on, the engine control module controls the throttle actuator precisely, following specifications from the throttle position sensor. That is, if the accelerator is half-way to the floor, then the throttle actuator opens the throttle valve to the same angle; the throttle valve is then opened approximately half-way. When the engine is running (under load), the engine control module can open or close the throttle valve independently of the sensor. As an example, the throttle valve can already be completely open, even though the accelerator has only been pressed half-way down so far. This has the advantage of preventing throttling loss at the throttle valve. Under certain load conditions, this also results in significantly reduced emissions and improved fuel consumption. It is wrong to believe that electronic throttle control only consists of two components. It is a system which contains all components needed to help determine, regulate, and supervise the throttle valve position (e.g. the throttle position sensor which measures the accelerator position, the throttle valve control module, the EPC indicator lamp, the engine control module). Page 5327 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit With Manufacturer's Scan Tool Idle Speed: Testing and Inspection With Manufacturer's Scan Tool Idle Speed, Checking NOTE: - Idle speed, ignition timing and CO content are not adjustable. - The idle speed is regulated to specified value by the throttle position sensor in conjunction with the DIS function. - CO content regulated by Oxygen Sensor (O2S) control. Malfunctions in oxygen sensor control are detected in On Board Diagnostic (OBD) and stored as DTCs in DTC memory Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Coolant temperature at least 85 °C See display group 004, display field 3. - Intake air temperature less than 60 °C See display group 004, display field 4. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes - Leave VAG1551 Scan Tool (ST) connected. - Continue running engine at idle speed. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -0- and -1- to input display group number 1 (001) and press -Q- button to confirm input. Indicated on display: (1-4= display fields) System in basic setting 1 -> 1234 NOTE: In the "Basic Setting" function the Evaporative Emissions (EVAP) canister purge regulator valve -N80- is closed and the air conditioner compressor is switched off - Check adjustment conditions for basic setting in display field 4. Page 5859 - Check electrolyte level visually, either via charge indicator (if equipped) or from min./max. markings on battery housing. Electrolyte level reading from charge indicator -arrow-. - Green -> electrolyte level OK - Colorless or yellow -> critically low electrolyte level. Top up with distilled water immediately CAUTION! Do not use charge indicator to determine excessive electrolyte levels. Always check for excessive electrolyte levels visually. Electrolyte level reading from min./max. marking on battery housing -arrow-. - Electrolyte level must be above the minimum marking or just reach the maximum marking. If no minimum and maximum markings are visible on the battery housing (either not molded-in or not visible due to installation location) or if the battery housing is black, the sealing plugs must be removed. Then determine electrolyte level by viewing inside the battery cells. - First remove plastic foil from cell caps (where applicable), being sure not to disturb plastic safety warning label on battery. Page 5185 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 3274 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Diagram 74/5 IMPORTANT NOTE: Page 5359 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Page 5872 - Remove bolt -1- on (+) positive terminal clamp. - Unclip and remove fuse holder mounting -2-. - Slide fuse box out from mounting in direction of -arrow-. - Lift fuse box away from battery and secure to front hood support with elastic cord. - Release battery positive terminal clamp securing bolt -arrow- and remove. - Remove screws -arrows- and remove cover -1-. Page 2501 Radiator Cooling Fan Control Module: Electrical Diagrams For information regarding diagrams for the Coolant Fan Control, please refer to the Heating and Air Conditioning System Diagrams 38\3 to 38\5 and 39\7 to 39\8 See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Air Conditioning - Manual, From May 1999/Diagram 38\3 (Track 15-28) See: Diagrams/Electrical Diagrams/Heating and Air Conditioning/System Diagram/Climatronic, From May 1999/Diagram 39/7 Also Shown in Coolant System Diagrams for Vehicles With Heater Only See: Radiator Cooling Fan/Diagrams/Electrical Diagrams/Coolant Fans, From May 1999/Diagram 37\2 (Track 1-14) Page 3245 Engine Control Module: Service and Repair Replacement ECM, Adaptation (Function 10) Replacement Engine Control Module (ECM), Adaptation (function 10) NOTE: - The engine control module is adapted to the immobilizer control module in the instrument cluster. When changing a component it must be readapted. - If an authorized ignition key is not available but the secret number is, new ignition keys must be manufactured and adapted. - The adapting can be interrupted with the "C" button of VAG 1551 Requirements Authorized ignition key available. - Insert old (authorized) key in ignition lock. - Connect VAG 1551, select operating mode 1, "Rapid data transfer". Switch ignition on and enter address word 17, "Instrument cluster". After control module identification has been displayed: Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Press -> button. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -1- and -0- to select function 10, "Adaptation". Indicated on display Rapid data transfer Q 10 - Adaptation - Press -Q- button to confirm input. Indicated on display Adaptation Enter channel number XX - Press button -0- twice to select "Channel O". - Press -Q- button to confirm input. Indicated on display Adaptation Q Erase learned value? - Confirm entry with -Q- button. Indicated on display Adaptation -> Learned values are erased - Press -> button. Indicated on display Rapid data transfer HELP Page 3560 Display Group 4 Evaluating display group 4, display field 4-Intake air temperature Page 1196 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no sensor malfunction is detected: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3- pin harness connector for open circuit according to wiring diagram. Terminal -1- + socket 108 - Terminal -2- + socket 90 - Terminal -3- + socket 82 - Wire resistance: max. 1.5 ohms - Additionally check wires for short to one another. If no malfunction is found in the wiring: - Remove sensor and check sensor wheel for secure fit, damage and run-out. NOTE: There is a larger gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If no malfunction is detected on sensor wheel: - Replace Engine Control Module (ECM). Page 5927 Warranty NOTE: For model years 2007 (after published VIN range) and newer, this is not a warrantable issue. Please consider this publication as information only. Required Parts and Tools No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 2816 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Ignition With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Service Precautions/Technician Safety Information Page 6451 Special tools, testers and auxiliary items required ^ Hydraulic removal and installing tool for wheel bearing V.A.G. 1459 B ^ Piston cylinder HKZ-15 with hydraulic press piece E0-204-T ^ Removal rods E-0-217+218 ^ Special nut E-8-214 Thrust tube E-5 ^ Thrust tube E-10 ^ Press sleeve E-13-1 ^ Thrust bolt E-15 ^ Supplementary set V.A.G. 1459 B/2 ^ Bell E-40 - Lift vehicle until the load on the front axle is relieved. - Loosen 12-point nut. - Lift vehicle to installing height. - Remove wheel. The following three work steps are necessary only for vehicles with modified stabilizer bar mounting. - Loosen upper hex nuts of connecting links from left and right suspension strut. - Pull out clamp on brake hose bracket and release brake hose. - Release speed sensor wiring from front suspension strut. Engine Controls - DTC's 00545/00638 Stored Engine Control Module: Customer Interest Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 3698 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Service and Repair Headlamp Dimmer Switch: Service and Repair The function of switching the high beams on and off is performed by the Combination Switch. Please refer to Combination Switch for further information. Page 2333 Part 1 Page 1059 Part 2 Page 2224 - Set both camshafts to TDC cyl. 1. - Align camshafts with camshaft guide 3268. - Install bearing bolt for tension bar and tighten to 18 Nm. - Install tension bar for chain tensioner (camshaft roller chain). - Install bearing bolt with collar for sliding rail and tighten to 10 Nm. Note: If the cylinder head is removed: Page 1073 Combination Switch: Service and Repair Steering Column Switch/ Combination Switch/ Turn Signal Switch Special tools and workshop equipment required - Torque Wrench -V.A.G 1331WARNING! Always follow the instructions regarding disconnecting and connecting the battery. Removing - Disconnect the battery. Please refer to See: Starting and Charging/Battery/Service and Repair - Remove driver's airbag. Please refer to See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair - Remove the steering wheel. Please refer to See: Steering and Suspension/Steering/Steering Wheel/Service and Repair - Remove the return ring with slip ring. Please refer to See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair - Disconnect the connectors from the steering column switch. - Loosen the clamping bolt of the steering columns switch -arrow- and pull the steering column switch rearward and off from the steering column. Installing - Install in reverse order of removal. Page 4039 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Locations Downshift Switch: Locations 4 Speed Automatic 01M Kickdown switch -F8Locations: Integrated into accelerator cable and is located on the bulkhead in the engine compartment. On vehicles which do not have an accelerator cable the kick-down signal is generated in the Throttle Position (TP) Sensor -G79- located near the accelerator pedal. Page 3372 If the specified values are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). Checking voltage supply - Connect multimeter using aux. cables from VW1594 to measure voltage at terminals -3- and -4(harness connector to Engine Control Module (ECM)). - Start engine and run at idle. - Measure voltage supply and observe display group 41, display field 2. Display: Htg.bC.ON Specified value: 11.0-14.5 V Display: Htg. bC.ON/Htg.bC.OFF (alternating) Specified value: Between 0.0-12.0 V fluctuating - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Service and Repair Steering Angle Sensor: Service and Repair Electronic Stability Program (ESP) Following steps are valid only for vehicles with Electronic Stability Program (ESP). Vehicles with ESP are additionally equipped with a Steering angle sensor -G85-. sensor is installed in conjunction with coil connector and slip ring in a housing. Removing - Front wheels and steering wheel must be in straight-ahead position. NOTE: Replacement slip ring is secured as a new part in center position with cable tie Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - Disconnect steering angle sensor connection. - Lift hooks - arrows - carefully and remove steering angle sensor. Installing - Install in reverse order of removal. For vehicles with ESP observe following: When installing, ensure steering angle sensor is correctly seated and is free of stress. - Front wheels and steering wheel must be in straight ahead position. - Remove transportation protection (cable tie) on markings before installing a new steering angle sensor. - Install steering angle sensor, until lugs engage. - Position steering wheels in central position; A yellow spot must be visible in hole - 1 -. marking arrow - must align. - A zero compensation must then be performed. Page 5138 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 235 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 4290 ^ The tester requests you to switch the ignition OFF. - Switch ignition OFF. ^ The tester requests you to switch the ignition ON. - Switch ignition ON when prompted. After switching ignition ON, the ECM has been re-initialized, however, fault memories must now be erased. - Select the "Continue button" Fault memories, erasing after "Update - Programming" (flashing) Due to the CAN bus system, fault messages will be stored in various Control Modules during programming. To erase ALL fault memories: - Confirm by selecting the right arrow --> button. Once fault memories have been erased: ^ Similar screen appears. ^ Old ECM Part No. and software level still appear at (arrow). ^ Function ended appears at bottom of screen. - Finish update of the ECM by selecting the left arrow <-- button. ^ Similar screen appears. Page 2111 No-Po Capacity Specifications Planetary Gears: Capacity Specifications Planetary Gearbox Capacities 01M Transmission Initial Filling .......................................................................................................................................... .......................................... 5.3 liter (5.6 quarts) Lubricant VW AFT ............................................................................................................................... ................................................. Part Number: 0.5 liter ........................................................................ ............................................................................................................................... G 052 162 A1 1.0 liter ....................................................................................................................................................... ................................................ G 052 162 A2 09A Transmission Initial Filling .......................................................................................................................................... .......................................... 7.0 liters(7.4 quarts) Lubricant VW AFT .............................................................................................................................................................. Part Number G 052 990 A2 Page 25 Alarm Module: Service and Repair Ignition Keys, Adaptation (Function 10) Ignition Keys, Adaptation (function 10) NOTE: - Replacement instrument clusters come with new secret numbers. Therefore, all keys must be adapted to the new cluster. - If new or additional ignition keys are required they must be adapted to the immobilizer control module. - Note procedure when changing the locking set and immobilizer control module. - Key adapting procedure must always be carried out for all ignition keys, including existing ones. - The number of keys already adapted will be displayed when adaptation (adapting) function is selected. - If only one key is adapted, the vehicle can be started immediately with this key. If more than one key has been adapted, the vehicle can only be started immediately with the last key adapted. - The adapting procedure can be interrupted by pressing -C- button on VAG 1551. CAUTION! The VAG 1551 dealership number (workshop code) will be stored in the immobilizer control module when adapting ignition keys. Requirements - All ignition keys currently in use on vehicle must be available. If no old ignition key is available see "Lost key procedure". - New vehicle key fob with covered secret number is available, if not see "Determining secret number". - Insert correct profile ignition key in ignition lock and switch on ignition. - Connect VAG 1551 Scan Tool, select operating mode 1 "Rapid data transfer", and enter address word 17, "Instrument cluster". - Press -Q- button to confirm input. - Press -> button until "Select function" appears in display. Indicated on display Rapid data transfer HELP Select function XX - Press button -1- twice to select "Login" function 11. Indicated on display Rapid data transfer Q 11 - Login procedure - Press -Q- button to confirm input. Indicated on display Login procedure Q Enter code number XXXXX - Read secret number located on the new vehicle key fob (visible by carefully "scratching off" protective coating, e.g. with a coin). NOTE: If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14-character immobilizer control module identification number. - Using VAG 1551 button pad, enter secret number (when doing so, insert 0 before 4 digit number, example: 01915). - Press -Q- button to confirm input. Indicated on display Rapid data transfer HELP Select function XX If this appears on display, secret number is not accepted: Tester sends address word 17 - Enter secret number again. Page 4181 Test Step 10 - 11 Page 415 Hazard Flasher Relay: Locations Auxilary Emergency Flasher RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 25 Nm Page 4918 - Install triple roller star, (chamfer on star faces shaft).. - Press star in to stop. - Install lock ring, and ensure lock ring clicks into groove. - Press in 60 grams (2.1 ounces) of grease G 000 633 (from repair set) into triple roller star. - Slide CV joint over roller and hold. - Press in 60 grams (2.1 ounces) of grease G 000 633 (from repair set) into back side of triple roller star. - Slide CV joint boot in place, bead in boot must lock into groove of CV joint. - Install new O-ring (arrow), from repair set, in groove. - Remove axle shaft from vice. NOTE: Holes from CV boot and joint must align. Page 3158 Electronic Power Control (EPC) Warning Lamp: Description and Operation Function of EPC system For EPC, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical connection between the accelerator pedal and the throttle valve. The position of the accelerator pedal is communicated to the Engine Control Module (ECM) via two sensors for accelerator pedal position (variable resistances; stored in one housing) that are connected with the accelerator pedal. The accelerator pedal position (driver's intention) is a main input unit for the ECM. Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle valve control module. This is true across the entire engine speed and engine load spectrum. The throttle valve is operated by the throttle drive according to the instructions of the Engine Control Module (ECM). With the engine at standstill and the ignition switched on, the Engine Control Module (ECM) activates the throttle drive precisely according to the specifications of the Throttle Position (TP) Sensor. This means, if the accelerator pedal is depressed half way, the throttle drive opens the throttle valve to the same degree; i.e. throttle valve is then opened approx. half way. With engine running (under load), the ECM can open or close the throttle valve independently of the sensor for accelerator pedal position. This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has only been depressed half way. This has the advantage of preventing torque losses at the throttle valve. In addition to this, it results in significantly better values relative to emissions and consumption under certain load conditions. It would be incorrect to think that "EPC" consists of only one or two components. EPC is much more of a system containing all components that contribute to assign, control and monitor the position of the throttle valve, e.g. sensor for Throttle Position (TP) Sensor, throttle valve control module, EPC warning lamp, Engine Control Module (ECM). Notes: - Engine Control Module (ECM) is equipped with On Board Diagnostic (OBD). - Components marked with * are tested via On Board Diagnostic (OBD) - Observe safety precautions. - Observe rules for cleanliness. - Servicing parts of the electronic Engine Power Control (EPC). Page 1339 - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Connect multimeter to terminal 2 of connector and engine Ground (GND) for voltage measurement. - Start engine, and let run at idle. Specified value: 11.0 to 15.0 V - Switch ignition off. If there is no voltage: - Check wire between 5-pin connector terminal 2 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If voltage supply and wires are OK: - Connect multimeter to terminal 4 of connector and engine Ground (GND) for voltage measurement. - Switch ignition on. - Specified value: at least 4.5 V Switch ignition off. If there is no voltage: - Check signal and Ground (GND) wire of Mass Air Flow (MAF) sensor. Checking signal and Ground wires of Mass Air Flow (MAF) Sensor - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Page 1680 - Fill with coolant up to upper mark on cross hatched area on coolant recovery bottle. - Close coolant recovery bottle. - Expose heater controls and turn-off air conditioning if necessary. - Start engine and run at approximately 2000 rpm for about 3 minutes. - Keep engine running until fan starts. - Check coolant level and fill as necessary. The coolant level must be within the cross-hatched region when the engine is running warm. It must be above the lower mark if the motor is cold. Page 5522 Note: After replacing the brake pads, depress the pedal firmly several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position. Page 4246 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 6069 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. Page 4900 - Press half of grease 40 grams (1.4 oz.) into joint body. - Install cage with hub in joint housing. - Press in balls one after another from opposite sides to restore original hub position to cage and joint housing. - Install new circlip in hub. - Install remaining grease in CV joint boot. Page 4146 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 1690 Final Drive Fluid: Testing and Inspection Final Drive Oil Level, Checking 4 Speed Automatic 01M Final drive oil level, checking The oil level may be checked with transmission installed The difference between Min. and Max. is 0.1 liters. Excess oil can be drawn off using extraction system V.A.G 1358 A. Checking Remove speedometer drive shaft and clean using a cloth. - Install and remove speedometer drive shaft, check oil level on shaft and, if necessary, correct. Final drive oil level must be between Min./Max. Page 6573 Air Register: Service and Repair Driver's Air Outlet, Removing Driver's Air Outlet (Golf And Jetta), Removing First do the following: - Turn (light switch) rotary switch to "0" position. - Press rotary part inward -1- and turn slightly to right -2- Hold rotary part in this position and pull light switch out -3-. - Disconnect electrical connection. - Remove screw -arrow-. - Pull out air outlet Jetta only: - Remove glove box - Disconnect electrical connection for air outlet illumination. Page 6006 Part 1 Page 2476 1. Pressure cap 2. O-Ring 3. Coolant recovery bottle 4. 10 Nm 5. Upper coolant pipe 6. To heat exchanger 7. Throttle valve control unit (J338) 8. To upper coolant hose 9. To upper radiator 10. Gasket 11. To lower radiator 12. Thermostat housing 13. Coolant feed pump (V51) 14. From heat exchanger 15. 25 Nm 16. Oil cooler 17. Screw plug 18. Coolant pipe 19. Coolant pump 20. 15 Nm 21. Pulley for coolant pump 22. 25 Nm 23. To Y-branch of - heat exchanger/coolant feed pump Page 2646 If the specified values are not attained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector terminals: Terminal 1 + socket 92 - Terminal -2- + socket 83 - Terminal -3- + socket 117 - Terminal -4- + socket 84 - Terminal -5- + socket 118 - Terminal -6- + socket 91 - Wiring resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive or Ground. Specified value: infinity ohms If no malfunction is found in the wiring: - Check Engine Control Module (ECM) voltage supply. Refer to "Engine Control Module (ECM) Voltage Supply, Checking", See: Engine Control Module/Testing and Inspection Page 4233 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams J104 - ABS Control Module Electronic Brake Control Module: Locations J104 - ABS Control Module J104 - ABS Control Module - in engine compartment, to left of vacuum brake booster - component of ABS Hydraulic Control Unit Page 2482 - Remove lower retaining screws in front wheel housing from bracket item - 5-. - Carefully remove auxiliary radiator with its attachments from below. Installing Installation is in reverse sequence, but observe the following directions: - Fill with coolant. Page 5543 Remove wheels and separate brake calipers from carrier as outlined in Repair Manual Group 44 Wheels, Tires, Vehicle Alignment and Group 46 - Brakes - Mechanical components in ElsaWeb. Brake Disc Inspection A detailed brake disc inspection is needed to determine if the brake disc should be machined or replaced. Inspect brake disc friction surfaces on both sides of the brake disc for: ^ Severe discoloration (bluing) ^ High heat surface damage (raised hard spots) ^ Visible cracks Brake discs showing any of the above described conditions MUST be replaced. Disc Thickness Measuring Each brake disc has the minimum allowed thickness cast, stamped or laser-etched into the disc hub. ^ Measure the brake disc thickness in 4 locations using either the Pro Cut International(TM) disc thickness measuring tool Part No. 50-902 or the Hunter Engineering Company disc thickness measuring tool Part No. 25-99-2. Measurements MUST be taken the same distance from the brake disc outer circumference to ensure consistency. Note Brake Disc Machining Tip: Page 2183 ^ Indicator lamp for oil pressure (K3) must illuminate for approximately 3 seconds after the ignition is turned on. ^ Oil temperature at least 80°C Oil pressure switch, checking - Remove the 1.4 bar oil pressure switch (F1) (black insulation) and screw it into the tester. - Screw the tester into the oil filter housing in place of the oil pressure switch. - Ground the tester brown lead H. - Connect the V.A.G 1527 B diode test lamp to the battery positive terminal (+) and to the oil pressure switch using the auxiliary cables from V.A.G 1594 A. The Light-Emitting Diode (LED) should not illuminate. If the LED illuminates: Replace the 1.4 bar oil pressure switch (F1). If the LED does not illuminate: Let the engine continue to idle. The light-emitting diode should light at 1.2-1.6 bar. Otherwise, replace the 1.4 bar oil pressure switch (F1). Oil pressure, checking Test condition ^ The VAG 1342 oil pressure test instrument is riot connected ^ Oil temperature at least 80°C Test sequence Start the engine and let it idle. Specification: oil pressure: at least 2.0 bar - Increase engine speed. ^ The oil should be at least 2.0 bar at 2000 rpm and 80°C oil temperature. ^ The oil pressure may not exceed 7.0 bar - Replace oil pump if necessary. Page 6328 - Apply tape to hold edges of leather to steering wheel substrate -arrow-. Leave tape on steering wheel for approx.30 minutes. - Remove tape from steering wheel starting at tape end closest to the outer diameter of the steering wheel and pulling toward center of steering wheel. - Use 3M(R) General Purpose Adhesive Cleaner (Part No.08987) to thoroughly clean leather wrap. - Repeat procedure on additional steering wheel spokes, as necessary. For Golf, GTI, Jetta, New Jetta, New Beetle, New Beetle Convertible, Passat, Passat Wagon and Touareg vehicles: - Install steering wheel.See Repair Manual, Body Interior, Repair Group 69. For Cabrio vehicles: - Install steering wheel.See Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 48. Warranty Required Parts and Tools Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Page 3620 - Press buttons -0-, -4- and -1- to input display group number 41 (041) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 41 -> 1234 - Check specified values for oxygen sensor heater in display field 2. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2744 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Diagram Information and Instructions Sunroof / Moonroof Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4433 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 393 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 5976 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Power Supply and Cables Check Electronic Throttle Control Module: Testing and Inspection Power Supply and Cables Check Checking the power supply and cables to the control module - Remove driver side shelf: - Disconnect 6 pin connector for throttle position sensor. - Turn on ignition. - To measure voltage, connect multimeter to following contacts of connector: Contact 1 + ground - Contact 1 + 5 - Contact 2 + ground - Contact 2 + 3 - Specification: at least 4.5 V - Turn off ignition. If the specifications are not achieved: - Connect VAG 1598/31 test box to control module wiring. Do not connect engine control module. Service and Repair Differential Output Shaft: Service and Repair 5 Speed Manual 02J Flanged shaft of seals, replacing Transmission installed Observe general repair instructions. Special tools and equipment - VW 771 Multi-purpose tool - VW 771/37 Puller hooks - 3106 Drift Removing Before replacing left-side oil seal: - Remove drive shaft. - Before replacing right-side oil seal: Turn steering to right onto full lock stop. - Remove drive shaft protective cap from engine, if installed. - Disconnect drive shaft from flanged shaft. - Tie up drive shaft as high as possible. Do not damage paint on drive shaft. - Place drip tray underneath. Page 6456 7. Brake caliper - Servicing - Refer to Brakes and Traction Control; Servicing rear brakes (disc brakes) 8. Stub axle - Straightening operations are not allowed - Recutting the thread is not allowed! Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Lift vehicle. - Remove wheel. Page 2956 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Page 2452 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 3106 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair - Compress coil spring with -VAG 1752/1- until upper spring plate is free. - Remove nut from piston rod. - Remove individual parts of suspension strut and coil spring with -VAG 1752/1-. 1 - Commercially available ratchet handle 2 - T 10001/8 3 - T 10001/11 4 - T 10001/5 5 - VAG 1752/1 Spring compressor 6 - VAG 1752/4 Retainer Special tool -3186- is an alternative for tools described above. - Ensure coil spring is seated correctly in adapter -VAG 1752/4 (arrow), Installing - Install coil spring with compressor -VAG 1752/1- on spring perch. Note: End of coil spring must lie against stop (arrow). Tightening torque: Nut for upper shock absorber mount 60 Nm (44 ft lb) Always replace nut! Nut for upper spring plate 60 Nm (44 ft lb) Page 5186 Part 1 Page 6371 - Remove module -J453- position -5- and -6- ,from relay carrier -A-. Installing - Install in reverse order of removal. - Coding multi-function steering wheel control module Control Unit In Steering Wheel -E221-, Removing and Installing Control Unit In Steering Wheel -E221-, Removing And Installing WARNING! Special safety precautions apply to vehicles equipped with airbags. Refer to Repair Manual, Body-Interior, Airbag: CAUTIONS and WARNINGS, Repair Group 69. CAUTION! Before working on the electrical system: - Determine the correct coding for the anti-theft radio. - Switch the ignition off - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual. Removing - Remove driver's airbag. - Remove bolts -arrows- from operating unit. Page 808 also transmitted to the Motronic Engine Control Module (ECM). Confirm G65 circuit using wiring diagram. - On vehicles where G65 is NOT connected to the ECM, connect green clip from VAG 1767 directly to G65 pin 2 using appropriate VAG 1594 adapter cable - 7 - . Proceed directly to checking. - Disconnect engine harness electrical connection from Engine Control Module (ECM) - 3 - . - Locate correct test box VAG 1598A - 4 - and adapter according to pin assignments of ECM - 3 and connect test box to engine wiring connector/harness - 2 - . - Connect black clip from VAG 1767 to Ground (GND) - 5 - . - Determine applicable G65 signal input pin assignment to ECM using wiring diagram. Example: T121/61 Note: As G65 function primarily controls coolant fan and A/C clutch operation, the engine wiring diagrams may indicate the G65 signal connection as being "Coolant fan control module connection" . - ECM terminal number assignments correspond with those on test box VAG 1598A . - Connect green clip from VAG 1767 to the corresponding numbered position on test box VAG 1598A connected to G65 pin - 2 - using appropriate VAG 1594 adapter cable - 7 - . Example: 61 Checking Switch ignition on. - Press button - arrow - for Duty Cycle measurement (modulation ratio) on ignition tester VAG 1767 (or select same function on equivalent device). Evaluating results Note: If a malfunction cannot be located, check DTC memory of Engine Control Module (ECM) and the Transmission Control Module (TCM) using VAG 1551/1552/1552 . When doing so, note that DTCs related to sensor G65 functions may be called-out as "A/C pressure switch -F129-" . Service and Repair Camshaft: Service and Repair Camshafts, removing and installing Special tools, equipment, test and inspection devices; required accessories - 3268 Camshaft ruler - VAG 1331 Torque wrench (5 - 50 Nm) or equivalent Removing - Turn camshaft in engine turning direction to marker TDC cyl. 1 -arrow- at oscillation damper retainer screw. - Remove ignition coil (N152). - Remove camshaft roller chain tensioner. - Remove cover. - Loosen fastening screws at camshaft sprockets. Page 6424 Always replace nut! Continue installation in reverse sequence. Page 2581 If after repairing other fault codes and setting readiness code, and any fault codes in the table return: Replace catalyst(s) as necessary, using applicable SRTs. If software updates do not apply, and only one or more of the following fault codes (DTCs) are present (see table): If DTC text indicates bank 2, bank 3, bank 4: Verify catalyst location before replacement, see Service Manual repair group 26. Use applicable SRTs. For technical assistance, select the "Technical Assistance" tab in ElsaWeb and follow the instructions to obtain a 6 digit pin. Tip: Before repairing vehicle or erasing fault codes (DTCs) remember to make print-outs including freeze-frame data as required and attach to the repair order. If catalytic converter is on parts submission, attach copies of all supporting documentation (including printouts) required when sending parts to Warranty Test Center. Page 2114 SW-Wu Diagram Information and Instructions Power Door Lock Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2056 3365 - Valve Seal Installer VW 541-1 A - Valve Spring Compressor Page 335 Part 2 Page 3643 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 639 Test table A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Locations A/C Pressure Switch F129 F129 A/C Pressure Switch - engine compartment, right rear Page 6168 Power Distribution Relay: Locations Power Supply (Terminal 30, B+) Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3910 Fuel Injector: Service and Repair Fuel Injection System Components, Removing and Installing. NOTE: Prior to removing the fuel injectors, the intake manifold must first be removed. 1 - 25 Nm. 2 - Intake Manifold Upper Section. Disassembling and Assembling, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine /Intake Manifold/ Service and Repair. See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Upper Section, Disassmbling and Assembling - Removing and Installing, refer to: Vehicle /Engine, Cooling, and Exhaust /Engine / Cylinder Head Assembly/ Valve Cover/ Service and Repair. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair 3 - Vacuum Connection. From Leak Detection Pump (LDP) - V144 -. - EVAP System. 4 - 81-pin Harness Connector. Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2046 - Ream valve guide with hand reamer 3120. You must use diluted soluble oil during this procedure. - Finish valve seats. Page 3084 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4182 Test Step 12 Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 3575 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Page 540 Engine Controls - DTC's 00545/00638 Stored Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 6130 Fuse arrangements in fuse holder, instrument panel left Page 1526 Rain Sensor: Electrical Diagrams Diagram 70/2 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 3989 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 4007 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Connect multimeter to measure voltage at terminals -2- and -6-. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. - Connect multimeter to measure voltage at harness connector terminal -2- and Ground. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If the specified values are not attained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Page 5865 - Battery equipped with permanent cell cover -2-. - Charge indicator -1- displays electrolyte level and charge condition. CAUTION! Under no circumstances should cover -2- be removed. Battery will be damaged and become unusable. NOTE: - As the charge indicator is located in a single cell, the indication is only valid for that cell. An exact assessment of battery condition should always be confirmed by performing a load test. See: - If the charge indicator on batteries in excess of 5 years old are colorless, DO NOT attempt to top and/or recharge battery. Battery must be replaced. - Air bubbles that occur normally during battery charging (even during vehicle operation) may adversely affect charge indicator reading. To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock the vehicle in order to displace any possible air bubbles that have formed. Charge indicator, readings - Green -> sufficient charge (and electrolyte level) OK - Black -> no charge or insufficient charge - Colorless or yellow -> replace battery Visual check Always carry perform a visual check of the battery before checking no load voltage, electrolyte specific gravity and load test. Check for: - Cracked battery case and resulting corrosion damage to surrounding area. - Loose, damaged or corroded battery posts and terminals. WARNING! - Ensure that all battery post/terminal connections are securely installed and tightened according to the torque value specified. - Intermittent contact at battery terminals may spark or cause electrical system malfunctions. No Load Voltage, Checking No Load Voltage, Checking CAUTION! - Battery cell caps must be screwed in tightly when charging, measuring voltage or performing load tests. - The following notes and procedures must be followed to ensure correct measurements. Special tools, testers and auxiliary items needed Automatic Rotary Switch For Sunroof, Removing (Meritor) Sunroof / Moonroof Switch: Service and Repair Automatic Rotary Switch For Sunroof, Removing (Meritor) Automatic Rotary Switch For Sunroof, Removing - Unclip trim - 1 - in direction of - arrow - and remove. - Remove bolts - arrows - and remove automatic rotary switch. - Unclip and disconnect connector. Page 4167 Test Step 1 4 Speed 01M Transmission Fill Plug: Specifications 4 Speed 01M Transmission 4 Speed 01M Transmission 1 Level Plug (with Overflow Line Tube)................................................................................................ .............................................................. 15 Nm 2 Fill Plug (with protective cap) Note: Always replace protective caps without spring retainers. The cap secures the plug. Page 2761 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Page 2955 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Page 3364 Display Group 032 Initiating learning process: Control module in Basic Setting scan tool function 04. Learning prerequisites for idle speed: - Idle speed - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C Coast Clutch Clutch: Service and Repair Coast Clutch 4 Speed Automatic 01M Freewheel with -B1 -piston, disassembling and assembling 1. Rollers - Installing see Fig. 1 2. Springs - Installing see Fig. 1 3. Cage - Installing see Fig. 2 - Securing see Fig. 3 4. Outer ring 5. Piston - Sealing lips are vulcanized to the piston - Moisten sealing lips with ATF before installing - Turn piston slightly when installing - Installed position see Fig. 4 Electrical - Battery Charging and Testing Information Battery: Technical Service Bulletins Electrical - Battery Charging and Testing Information 27 10 01 May 26, 2010 2011894 Supersedes T.B. Group 27 number 08-06 dated Sept. 30, 2008 due to addition of VAS 6161 and additional battery instruction and specifications. Vehicle Information Condition Battery, Testing and Charging Using Midtronics VAS6161, MCR340V Analyzer or InCharge 940 Charging Station Note: This technical bulletin covers testing and repair procedures for multiple vehicle lines, model years and engine combinations. To prevent mis-diagnosis, you must ensure that the testing/repair procedure is applicable to the vehicle you are servicing. Technical Background The VAS6161, MCR340V and In-Charge 940 (INC-940) are the only VW approved battery testers and chargers that can be used to test and charge batteries in VW vehicles. Use of non-approved battery testers and chargers is not allowed, as internal battery damage may occur. Production Solution No production change required. Service WARNING Danger of injury! Prior to handling or servicing batteries, read, understand and observe all Warnings and Safety Measures for lead-acid batteries. Note: In order to prevent damage to battery or vehicle, observe battery type descriptions and notes. Tip: ^ Switch off all electrical consumers. ^ Switch ignition OFF and remove ignition key. Battery Testing/Charging Sections: 2-1 All Models 1998 - 2010, Except New Passat 3.6L, Eos 3.2L, Golf VR4/R32, Touareg, Phaeton and Routan 2-2 B6 Passat, Passat Wagon and CC with 3.6L 2006-2010 (Rear Battery) 2-3 Eos 3.2L 2006 - 2008 2-4 Golf VR4/R32 2010 2-5 Touareg 2004 - 2010 2-6 Phaeton 2003 - 2006 2-7 Routan 2009 - 2010 2-8 MCR340V, INC-940, Trouble Shooting Error Messages 2-1 All Models 1998 - 2010, Except New Passat 3.6L, Eos 3.2L, Golf VR4/R32, Touareg, Phaeton and Routan Tip: DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions: ^ Battery was removed for a separate repair prior to performing battery test. Page 3944 - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Vehicles with engine code BDF - Disconnect fuel supply line -1- (black) from fuel distributor and catch escaping fuel using a rag. Page 5740 ABS Control Module W/Electronic Differential Lock And Anti-slip Control (ASC) From August 2000 Control Modules - Connector Pin-out Page 4325 Shift Interlock Solenoid: Service and Repair 5 Speed Automatic 09A Shift lock solenoid -N110-, removing and installing Removing Check whether a coded radio is fitted. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - Switch ignition off and disconnect battery Ground strap. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - -Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Unclip shift lock solenoid -N110- from retainer arrows A-. - Pull solenoid out of locking pawl -arrow B-. Page 5103 Test table Page 5240 Test Step 3 - 6 Locations Cruise Control Switch: Locations Cruise Control Switch -E45Location: on steering column switch Page 2795 - Measure sensor resistance between terminals 2 + 3 at connector to sensor. Specified value: 480...1000 Ohm - Check sensor for shorts between terminals 1 + 2 and 1 + 3. Specified value: infinite Ohm If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28-: Vehicles with engine code AFP, item 25, - Vehicles with engine code BDF, item 16. - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 108 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no DTC is found on sensor: - Connect test box to control module wiring harness connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Terminal 2 + socket 90 Terminal 3 + socket 82 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Remove sensor and check sensor wheel for secure fit, damage, and run-out. NOTE: There is a larger-sized gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If nothing seems to be wrong with the sensor wheel: - Replace Motronic Engine Control Module (ECM) -J220-. Page 3365 Learning prerequisites for part load: - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C If the specified value is obtained: - Change to display group 33 as follows: - VAG1551: Press button 3 - VAG1552: Press button up arrow Indicated on display: (1-2 = display fields) Read Measuring Value Block 33 -> 12 - Observe Oxygen Sensor (O2S) control in display field 1. If the specified value is obtained: Display Group 033 If the specified value is obtained: Page 3736 - When transmission has been securely supported, remove bolts for transmission carrier (arrows). - Remove pendulum support (arrows). - Lower transmission approx. 60 mm (2.4 in.) -a-. - Disconnect black connector from sensor. - Remove bolt and take sensor -1- out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 3788 Display Fields - Press - button. - Check DTC memory. - Read readiness code. - If fault memory has been erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. If the indictor behaved as described: Release brake pedal. - Press C button. Diagnosis of catalytic converter Note: This diagnosis will only exit if the diagnosis of the aging of the oxygen sensors has already been completed successfully. Indicated on display Press "0", "4" and "6" for display group 46 and acknowledge with "Q." Page 1028 - Prior to Installation, pull out brake switch plunger (black arrow) to full extension. - Apply a light coat of lubricant Part No. G 052 142 A2 to end of plunger (black arrow). Lubricant is considered shop supply. - Keep brake pedal in the up position (IMPORTANT! hold pedal up if necessary while installing switch). - Push switch in and seat fully into opening (pressing plunger against pedal to adjust). - Once seated, secure switch by turning it to the right approx. 45° (must be turned fully to it's stop! see magnified views below). ^ This action turns the plunger shoe into the correct orientation to make electrical contacts in switch operate as well as locks in plunger (arrow) adjustment. Once installed, inspect internal stop pin of switch (inset) for correct positioning (see examples below). CAUTION! When installing, the switch must be rotated until it is fully locked and electrical connector is in the horizontal position. Page 6100 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 1637 Ribbed Belt: Service and Repair Serpentine Belt Ribbed belt routing NOTE: Before removing ribbed belt, mark direction of rotation. When installing the belt ensure it is correctly seated in the pulley. 1 - Ribbed belt tensioner 2 - Generator pulley 3 - Compressor pulley 4 - Power steering pump pulley 5 - Crankshaft pulley/vibration dampener 6 - Water pump pulley Page 3348 Display Group 030 Explanation of 3 digit number block in display field 2 With Manufacturer's Scan Tool Ignition Coil: Testing and Inspection With Manufacturer's Scan Tool Ignition Coils With Power Output Stage, Checking Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - VAG1527B voltage tester - Wiring diagram Check conditions - Fuse 29 must be OK - Battery voltage at least 11.5 V - Engine speed (RPM) sensor -G28- OK. Refer under "Powertrain Management/Computers and Control Systems/Engine Speed Sensor", See: Computers and Control Systems/Engine Speed Sensor/Testing and Inspection - Camshaft Position (CMP) sensor -G40- OK. Refer under "Powertrain Management/Computers and Control Systems/Camshaft Position Sensor", See: Camshaft Position Sensor/Testing and Inspection Test sequence - Disconnect 5-pin harness connector from ignition coil (arrow). Checking voltage supply Page 5396 SUBLETS At -A- Glance For vehicles that, according to your information, cannot be corrected, and one of the codes below best describe the reason, please enter into the system one of the codes indicated, as applicable: Campaign Verification For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding campaign inquiry and verification system; other systems are not valid and may result in non-payment of a claim. Dealer Obligation To ensure customer satisfaction, as well as minimize inconvenience to your customers, you are urged to service each vehicle at the scheduled service appointment time, supply a loaner vehicle for the day. Make sure that each vehicle is returned to the customer washed and cleaned inside. In the event the customer waits during the service, do not let them wait longer than specified for the recall repair service in the owner notification letter. Please make every effort to reduce inconvenience to customers. Service Help Dealer Personnel Information Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel. Thank you for your cooperation. Overview This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Page 3758 - Disconnect 2-pin connector from motor for secondary air pump (arrow). Continuation for all vehicles - Disconnect pressure hose at Secondary Air Injection (AIR) pump motor. NOTE: To disengage, compress the buttons at the hose coupling. - Connect Secondary Air Injection (AIR) Pump Motor to the B+ and Ground (GND) terminals of the battery using the respective adapter cables. The Secondary Air Injection (AIR) Pump Motor must start up and air must escape at compressed-air connection (arrow). If the motor does not start up, or no air or only very little air escapes: - Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery. - Replace Secondary Air Injection (AIR) Pump Motor -V101-. Vehicles with engine code AFP, item 19, - Vehicles with engine code BDF, item 20. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If motor starts, and air escapes: - Disconnect connection between Secondary Air Injection (AIR) Pump Motor and battery. - Remove Secondary Air Injection (AIR) pump relay from relay carrier in protective housing for control modules: Vehicles with engine code AFP, see Fig. 1. Fig. 1 Relay position assignment in protective housing (engine compartment, left) Page 9 After DTC memory has been successfully checked: Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -5- to select "Erase DTC memory" function 05. Indicated on display Rapid data transfer Q 05 - Erase DTC memory - Press -Q- button to confirm entry. Indicated on display Rapid data transfer -> DTC memory is erased! DTC memory is now erased. - Press -> button. Indicated on display Rapid data transfer HELP Select function XX NOTE: If this appears in the display, the test sequence is faulty. Warning! DTC memory was not checked If this appears in the display, the test sequence is faulty. Rapid data transfer -> DTC memory was not checked Adhere exactly to test sequence: First check DTC memory and, if necessary, repair any malfunctions. Page 1156 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 5914 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Page 6001 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1171 If the display does not change: - Disconnect 2-pin harness connector from clutch vacuum vent valve switch -F36-. - Measure resistance between switch terminals -1- and -2-. - Specified value without clutch depressed: max. 1.5 ohms - Specified value with clutch depressed: max. infinity ohms If the specified values are not obtained: - Replace clutch vacuum vent valve switch -F36-. NOTE: Observe installation position of clutch pedal switch in bearing bracket upper assembly hole. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased of the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specified values are obtained: - Connect multimeter to measure voltage between terminal -1- and Ground (GND). - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring for open circuit between 2- pin harness connector terminal -1- and central electrics using wiring diagram. If the specified values are obtained: - Remove wiper arms and plenum chamber cover. Page 2631 Page 4940 Loosen dust cap from seat by tapping lightly on the claw with hub cap puller VW637/2 . - Pull off dust cap. - Remove securing bolts - A - from brake caliper. - Remove brake caliper and hang up on body. - Remove Phillips-head screw for brake disc and take out brake disc. - Remove 12-point nut. Page 3612 - Check status of the oxygen sensor control before Three Way Catalytic Converter (TWC) (display field 1). Display Group 030 Explanation of 3 digit number block in display field 1 Page 169 Part 1 Page 2101 Ag-Ig Page 1454 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Wheel Speed Sensor on Front Axle Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Front Axle Note: Removing and installing ABS system components is identical for FS III and FN 3 brake calipers. 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant, G 000 650 2 Wheel bearing housing 3 Hex socket head bolt, 8 Nm (70 inch lbs.) 4 Splash shield 5 Hex bolt, 7 Nm (62 inch lbs.) 6 Wheel bearing ^ Replace each time after removing 7 Screw 8 Brake disc 9 Wheel hub with ABS wheel speed sensor rotor ^ Pressing out and in 10 Circlip Wheel speed sensor for front axle, removing and installing Removing ^ Raise vehicle. Page 2995 NOTE: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator: - Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. - Switch ignition off. - Now check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow -arrow-). - Observe pressure drop on pressure gauge. If pressure does not drop: - Test check-valve of Fuel Pump (FP), Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking If pressure does drop again: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator: Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. If pressure does drop again: - Check whether line connections, O-rings in fuel rail, and fuel injectors are properly sealed. - Check whether pressure gauge is properly sealed. NOTE: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. Page 2332 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5115 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Page 2896 Part 1 Page 3744 - Remove intake hose to combination valve at air filter upper part (arrow) and blow into it with light pressure. Combination valve must close. NOTE: To disengage, compress the buttons at the hose coupling. - Operate vacuum pump. Combination valve must open. If the combination valve does not open or it is constantly open: - Replace combination valve. Vehicles with engine code BDF NOTE: Do not use pressurized air for the following test. - Remove engine cover. - Remove intake air hose between Mass Air Flow (MAF) sensor and throttle valve control module, item 16. - Disconnect vacuum hose from Secondary Air Injection (AIR) Solenoid Valve -N112- at combination valve (arrow). - Connect hand vacuum pump ((V.A.G 1390) to vacuum connection of combination valve (arrow). Page 3672 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (5 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission) Page 2045 Valve Guide: Service and Repair Valve guides, replacing Special tools, equipment, test and inspection devices; required accessories - Hand reamer 3120 and diluted soluble oil - 3121 Driver Removing - Clean and check cylinder head. Heads whose valve seat rings cannot be finished any further, or heads which have already been finished to minimum measurement, or which already have KD valve guides installed, are unsuitable for valve guide replacement. - Press worn valve guides out from camshaft side by using driver 3121. Installing - Sprinkle new guides with oil and press them up to sleeve into cold cylinder head. Cylinder head must be laying down flat during this procedure. Note: After the guide is in place with the sleeve, the pressure of pressing down cannot exceed 1.0 t, otherwise the sleeve might break off. Page 4784 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 2547 10. Coolant temperature sensor (G62) - With coolant temperature display sensor (G2) - For engine control module - If necessary, release pressure from cooling system before removing Page 6119 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 4075 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) Service and Repair Fuel Door Switch: Service and Repair Switch For Fuel Tank Door -E204-, Removing And Installing Removing - Place screwdriver behind switch housing and carefully pry out of retainer. - Disconnect electrical connections. Installing - Connect electrical connector. - Insert switch into retainer and clip-in. Locations Radiator Cooling Fan Control Module: Locations J293 Coolant Fan Control (FC) control module - engine compartment, lower left, below front longmember Page 4493 - Place drip tray under transmission. - Bring ATF to test temperature. Test temperature: 35°C to 45°C - Remove ATF inspection plug from transmission housing (arrow). At first the ATF present in the overflow pipe (arrow 2) will run out. - Observe amount of ATF draining from plug hole afterward. If ATF continues to drip out of hole: ATF need not be topped up. - Install new seal (arrow 1) to ATF inspection plug and tighten to 15 Nm. ATF check is completed. - End output with V.A.G 1551. See below. If the ATF present in the overflow pipe runs out of the plug hole but no further draining is observed: Top up ATF in transmission. ATF, Topping Up With engine running. WARNING: When working in the vicinity of the radiator, always maintain a safe working distance - Danger of injury! - Fan could start automatically. Page 5733 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 5718 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 1400 Impact Sensor: Service and Repair Crash Sensor, Rear Side Airbag, Remove and Install Crash Sensor For Rear Side Airbag, Driver's And Passenger Sides, Removing And Installing In certain accident situations, the "rear crash sensor for side airbag" can initiate deployment of side curtain protection and side airbag. The "rear crash sensor for side airbag, driver's and passenger sides" is known as "electronic control unit side curtain protection" in case of replacement part Removing WARNING! Before working on electronic components, disconnect the battery ground (GND) strap NOTE: - Before disconnecting battery cables, take all notes into account regarding coding in radio operating instructions. - After reconnecting the battery cables, check vehicle equipment, such as radio, clock and window regulator. - Remove wheel house trim (Golf). - Remove wheel house trim (Jetta). Alloy Wheels - Cleaning Procedure Wheels: Technical Service Bulletins Alloy Wheels - Cleaning Procedure Group: 44 Number: 01-05 Date: Aug. 21, 2001 Subject: Alloy Wheels, Cleaning Model(s): All with Alloy Wheels Supersedes T.B. Group 44 number 01-04 dated Aug. 16, 2001 due to Part No. correction. Condition Alloy wheels have a build-up of road dirt or brake dust. Service CAUTION! Some aggressive, harsh wheel cleaners can damage the finish on alloy wheels. Always read and follow manufacturer Cautions and Warnings regarding use of product. - Alloy wheels can be cleaned without damaging the wheel finish by using Alloy Wheel Cleaner Part No: ZVW 902 106. - Follow detailed instructions on wheel cleaner container. Note: Please in form your customers regarding the recommended cleaning of alloy wheels. Cleaning alloy wheels is NOT covered under the New Vehicle Warranty Page 40 - Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM). - Press mix button briefly again. ^ Screen indicates number of stations broadcasting close to frequency band of selected station. ^ As the number increases for [mp] and (adj], static and signal crossing will increase. To exit service mode: - Depress and hold the mix button or switch radio OFF then back ON Navigation units ^ No internal diagnosis functions. Continue to antenna lead diagnosis. Section 3 - Antenna Lead Diagnosis After initial radio diagnosis using internal service functions, use the following procedures: - Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base. - Check for proper connection. (follow steps for your type of system). - For all systems, locate cable end-point at either diversity box or antenna mast base. - Disconnect cable from either diversity box or antenna mast base. - Carefully ground center wire in cable to chassis. If reception returns: ^ Cable and radio are ok. Page 2868 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor After TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control After TWC, Checking, With Manufacturer's Scan Tool. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control After TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 2974 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Ignition Page 156 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5664 Vacuum Brake Booster: Service and Repair Removing and Installing Special tools and equipment required ^ 3094 Hose clamps or equivalent Removing ^ Note or request radio code on vehicles with coded radio if necessary. ^ Disconnect battery. Vehicles with manual transmission ^ Clamp clutch master cylinder supply hose with special tool 3094 or equivalent. ^ Remove clutch master cylinder supply hose from reservoir. All vehicles ^ Remove ABS control module and hydraulic unit. ^ Disconnect vacuum hose from brake booster. Vehicles with automatic transmission ^ Remove connector -1- from retainer -2-. ^ Separate connector -1-. All vehicles Page 6052 Power Distribution Relay: Locations Power Supply (Terminal 30, B+) Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5301 Page 6144 Fuse Block: Service and Repair Fuse Holder on Battery, Removing and Installing Fuse Holder On Battery, Removing And Installing NOTE: Obtain connector pin assignment from respective wiring diagram! Page 1384 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes 4 Speed Automatic 01M Control Module: Service and Repair 4 Speed Automatic 01M Removing TCM -J217- Switch ignition off. - Remove wiper arms and plenum inner cover. - Release multi-pin connector, then remove connector from control module. - Remove screws (arrows). - Remove control module. Installing TCM -J217Installation is performed in the reverse order of removal. Page 630 Test Step 2 - 3 Test Step 4 OE did not furnish a "Test Step 4". Service and Repair Air Bag(s) Arming and Disarming: Service and Repair When working on the airbag system, the vehicle battery ground (GND) strap must be disconnected. No waiting time is necessary after disconnecting the battery. When connecting the airbag system to a voltage source no person can be present inside the vehicle. Steps for performing repairs on airbag system. 1. Disconnect battery ground (GRD) strap. 2. After installing/repairing of components is completed, switch on ignition. 3. Close doors. 4. Connect battery ground strap. Visual and functional check of airbag warning light system. - The warning light must light for approximately 3 seconds when the ignition is switched on. - The warning light must switch off after approximately 3 seconds and then not light again or flicker during a road test. Observe additional service precautions. See: Restraint Systems/Air Bag Systems/Service Precautions Page 5564 ^ Remove seal using wedge 3409. Installing ^ Apply a thin coat of assembly lubricant G 052 150 A2 to piston and seal before inserting. ^ Place protective seal with outer sealing lip on the piston. ^ Hold piston in front of caliper housing and install inner sealing lip into groove in cylinder using wedge 3409. Page 266 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir Page 1907 7. Brake caliper - Servicing - Refer to Brakes and Traction Control; Servicing rear brakes (disc brakes) 8. Stub axle - Straightening operations are not allowed - Recutting the thread is not allowed! Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes Wheel Bearing/Wheel Hub on Vehicles With Disc Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 ^ Fitting sleeve 3241 ^ Assembly tool 3420 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A.G. 1410 Removing - Lift vehicle. - Remove wheel. Page 3582 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 6447 11. Ball joint ^ Checking; Refer to Ball joint; Testing and Inspection 12. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 13. Shield plate 14. Hex bolt, 10 Nm (89 in lb) 15. Hex bolt ^ For special model "Golf GTI 132 kW" ^ Always replace 16. Self-locking 12-point nut ^ Always replace 17. Phillips screw, 4 Nm (35 in lb) 18. Ventilated brake disc 19. Wheel hub with speed sensor rotor ^ Rotor is welded to wheel hub 20. Circlip ^ Make sure seated correctly 21. Wheel bearing ^ Pressing wheel bearing out of wheel bearing housing ^ Replace, as it is destroyed during pressing out ^ Pressing wheel bearing into wheel bearing housing 22. Wheel bearing housing For vehicles: ^ With gasoline engines from 110 kW (147.5 Hp) Pressing wheel hub out of wheel bearing housing Page 4569 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Page 3661 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 3113 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 2-pin harness connector using wiring diagram. Terminal -2- + socket 39 - Wire resistance: Max. 1.5 ohms - Additionally, check wires for short to one another. - Additionally, check wiring for short to battery positive (B+) or Ground (GND). Page 2406 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 1579 Delivery rate has been obtained, but malfunctions are still suspected in the fuel supply (e.g. sporadic loss of fuel supply): - Check Fuel Pump (FP) current draw as follows: - Reconnect all disconnected fuel lines. - Connect multimeter with electrical current probe to wire of 4-pin connector (terminal 1 arrow) from wiring harness. - Start engine and let run at idle. - Measure Fuel Pump (FP) current draw. Specified value: max: 8 amperes NOTE: If disturbance in fuel system is sporadic, test can also be performed during a road test, but a 2nd person is required. If current draw is exceeded: - Fuel Pump (FP) faulty, replace Fuel Pump (FP), see Fuel Pump (FP), removing and installing. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Central Control Module For Comfort System Connectors Body Control Module: Locations Central Control Module For Comfort System Connectors Central control module for comfort system Air Flap Motors (For Climate Control Regulation), Replacing Air Door Actuator / Motor: Service and Repair Air Flap Motors (For Climate Control Regulation), Replacing Air Flap Motors (for Climate Control Regulation), Replacing CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. NOTE: After installing flap motors: - Ensure wiring is correctly routed. Harnesses must be routed so that they do not come into contact with moving parts (for example the levers on the flap motors). - Initiate Basic setting, function 04 See Climatronic OBD. Air flow flap motor -V71-, removing and installing NOTE: The air flow flap motor also operates the fresh/recirculating air flap. Removing - Remove glove box. - With screwdriver, carefully unclip air flow flap rod -1- from lever -2-. - Disconnect electrical connector -1-. - Remove screw -3-. The flap motor is connects to the evaporator housing portion of the heating and A/C unit. To prevent damage: - Lower flap motor and at the same time pull off fresh air/recirculating air flap shaft -2-, arrow -A-. Locations Manifold Pressure/Vacuum Sensor: Locations G71 - Manifold Absolute Pressure (MAP) sensor Page 6343 Service and Repair Air Cleaner Housing: Service and Repair 1 - Harness connector Black, 2-pin - For Positive Crankcase Ventilation (PVC) heating element -N79- Check heater element voltage supply between terminals 1 and 2 with engine running: - Specified value: at least 11.5V 2 - Connecting hose For air circulation of fuel injectors 3 - Intake hose Note installation position 4 - Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-* Checking -G70-. Refer under "Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor", See: Powertrain Management/Computers and Control Systems/Air Flow Meter/Sensor/Testing and Inspection - Checking - G42-. Refer under "Powertrain Management/Computers and Control Systems/Air Temperature Sensor", See: Powertrain Management/Computers and Control Systems/Intake Air Temperature Sensor/Testing and Inspection - Sensor and harness connector terminals are gold plated 5 - Harness connector Black, 5 pin - Sensor and harness connector terminals are gold plated 6 - Seal Always replace if damaged 7 - Air cleaner upper section Page 331 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Locations Transmission Temperature Sensor/Switch: Locations G93 - Transmission Fluid Temperature Sensor, 01M (Items 13/14/17 - Conductor Strip with Integrated Transmission Fluid Temperature Sensor -G93-) Page 5090 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Page 1161 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Page 4101 - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at connectors to knock sensors. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 15 , - Knock Sensor (KS) 2 -G66-, item 11 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking resistances and wires (Vehicles with engine code BDF) Page 3260 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Service and Repair Valve: Service and Repair For further information regarding this component please refer to Cylinder Head; Service and Repair. Page 1497 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4440 Page 3835 - Connect pressure gauge V.A.G 1318 to adapter V.A.G 1318/10 at supply hose -1- and to adapter V.A.G 1318/11 and hose adapter V.A.G 1318/16 at supply line. - Open shut-off valve of pressure gauge. The lever points in the direction of flow (arrow). Continuation for all vehicles - Start engine and let run at idle. - Measure fuel pressure. Specified value: about 2.5 bar positive pressure Vehicles with engine code AFP - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Vehicles with engine code BDF - Disconnect vacuum hose from fuel pressure regulator (arrow). Fuel pressure should rise to about 3.0 bar positive pressure. Continuation for all vehicles Page 4571 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Page 1501 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 4816 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5644 Brake Master Cylinder: Service and Repair Brake master cylinder Special tools and equipment required ^ 3094 Hose clamps or equivalent Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery. ^ Disconnect or connector -1- of Mass Air Flow (MAF) sensor from air filter tube. ^ Remove bolts -2- at air filter -3- and move filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. ^ Spread sufficient lint-free cloths in area of plenum, and on engine and transmission to catch any escaping brake fluid. ^ Using a bleeder bottle, draw off as much brake fluid as possible from brake fluid reservoir. ^ Clamp clutch master cylinder supply hose with clamp 3094. ^ Remove clutch master cylinder supply hose from reservoir. ^ Disconnect brake fluid level sensor wiring connector. Vehicles with automatic transmission Page 4489 Sealing plug (arrow 3) and cap (arrow 4) remain closed. If the ATF present in the overflow pipe runs out of the plug hole but no further draining is observed: Top up ATF in transmission. ATF, Topping Up With engine running. - Pry off plug securing cap -arrow- with a screwdriver. Cap locking device will be damaged, therefore always replace cap. - Remove plug from filler pipe. - Fill with ATF using V.A.G 1924 until ATF runs out of plug hole -arrow-. Note: An insufficient ATF filing as well as filling to excess affects the function of the transmission. - Install new seal to plug -arrow 1- and tighten to 15 Nm. - Install plug on filler pipe and secure with a new cap -arrow 2-. - Lock cap. Note: Always replace the cap. The cap secures the sealing plug. Page 3472 Engine Control Module: Application and ID Control Module Identification and Equipment Control Module Identification The control module version is displayed when the VAG1551 Scan Tool (ST), the VAG1552 mobile scan tool or the VAS5051 vehicle diagnostic, testing and information system is connected and "Engine Electronics" address word 01 is selected See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Manufacturer's Scan Tool/Connecting VAG 1551 Scan Tool Technical data Engine code AFP System designation Motronic ME7.1 Exhaust emissions conform to: OBD II On Board Diagnostic (OBD) yes Output Diagnostic Test Mode yes Operating mode of data transfer to VAG1551/1552 Rapid data transfer DTC memory Non-volatile memory 1) Readiness Code Memory Volatile memory 2) Heated Oxygen Sensors (HO2S) 2 sensors Knock control 2 knock sensors Twin-path intake manifold yes Variable valve timing no Charge pressure control no Secondary Air Injection (AIR) system yes 1) Independent of voltage supply. 2) Values are erased when voltage supply is interrupted. Service and Repair Engine Mount: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Bonded Rubber Bushing For Control Arm, Replacing Control Arm Bushing: Service and Repair Bonded Rubber Bushing For Control Arm, Replacing Fig. 1 Front control arm bushing, pressing out Fig. 2 Front control arm bushing, pressing in NOTE: ^ To aid pressing in use oil G 294 421 A1 Never use grease! Page 1378 Management/Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 6222 After tightening lock nut -1- it is possible for adjustment to vary slightly. If value does not vary more than 2' from specification, adjustment is ok. Ensure that boots are not twisted after adjustments are completed. Page 2331 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6113 Fuse arrangements in fuse holder, instrument panel left Fuse Arrangements In Fuse Bracket/Battery Page 4303 - Test-drive vehicle and inspect transmission for signs of leakage. Page 1480 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3570 - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1744 Final Drive Fluid: Fluid Type Specifications Final Drive Fluid Type Synthetic Oil SAE 75W90 Part Number: ....................................................................................................................................... .............................................. 0.5 liter G 052 145 A1 Part Number: .................................................... ................................................................................................................................. 1.0 liter G 052 145 A2 Page 2678 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 5897 Special tool -socket 3310- is required to loosen/tighten ribbed belt pulley on generator. Ribbed belt pulley securing nut tightening torque: 65 Nm ± 5 Nm. Not Available For Manufacturer's Scan Tool Variable Valve Timing Actuator: Testing and Inspection Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. Page 510 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Symptom Related Diagnostic Procedures Battery: Symptom Related Diagnostic Procedures Battery Discharges (Current Draw Suspect) Test condition: Battery voltage OK. Possible causes of battery drain: - corroded and dirty contacts (connectors) - bare wires (stripped insulation) - Internal short circuits in components Required for troubleshooting: - Multimeter Fluke 83 - Connector Test Kit VW 1594 - Valid wiring diagram NOTE: Please ensure that no run-on functions are active while measuring the battery discharge current (e.g. after-run coolant pump, coolant fan etc.) Ensure the anti-theft code is obtained fore a radio with anti-theft coding, before disconnecting the battery. (All the vehicle equipment/radio, electric windows etc.) must be checked/ tested according to the Repair Manual and/or the Owners Manual when the battery is reconnected. Page 2807 - Spray the sensor (arrow) with commercially available chilling spray and watch the temperature value. The temperature should decrease. - End diagnosis and switch ignition off. If the intake air temperature does not drop: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Continuation of test if indication is approx. -40 degree C: - Disconnect 5-pin connector from Mass Air Flow (MAF) Sensor -G70- with Intake Air Temperature (IAT) Sensor -G42- (arrow). - Bridge terminals 1 + 3 of connector using the respective adapter cables while observing the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. Page 896 also transmitted to the Motronic Engine Control Module (ECM). Confirm G65 circuit using wiring diagram. - On vehicles where G65 is NOT connected to the ECM, connect green clip from VAG 1767 directly to G65 pin 2 using appropriate VAG 1594 adapter cable - 7 - . Proceed directly to checking. - Disconnect engine harness electrical connection from Engine Control Module (ECM) - 3 - . - Locate correct test box VAG 1598A - 4 - and adapter according to pin assignments of ECM - 3 and connect test box to engine wiring connector/harness - 2 - . - Connect black clip from VAG 1767 to Ground (GND) - 5 - . - Determine applicable G65 signal input pin assignment to ECM using wiring diagram. Example: T121/61 Note: As G65 function primarily controls coolant fan and A/C clutch operation, the engine wiring diagrams may indicate the G65 signal connection as being "Coolant fan control module connection" . - ECM terminal number assignments correspond with those on test box VAG 1598A . - Connect green clip from VAG 1767 to the corresponding numbered position on test box VAG 1598A connected to G65 pin - 2 - using appropriate VAG 1594 adapter cable - 7 - . Example: 61 Checking Switch ignition on. - Press button - arrow - for Duty Cycle measurement (modulation ratio) on ignition tester VAG 1767 (or select same function on equivalent device). Evaluating results Note: If a malfunction cannot be located, check DTC memory of Engine Control Module (ECM) and the Transmission Control Module (TCM) using VAG 1551/1552/1552 . When doing so, note that DTCs related to sensor G65 functions may be called-out as "A/C pressure switch -F129-" . Page 5734 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 2980 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 2460 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1476 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Page 4716 1. Selector lever handle - Press sleeve -item 2- down and pull handle off upward. 2. Sleeve - Locates in the selector lever handle - Prevents selector lever handle from being pulled off 3. Cover - With selector indicator - Clipped into frame -item 74. Cover strip - Insert in frame -item 75. Selector lever position display - Printed circuit for selector lever position display (illumination) is held in position by clips - Contacts for selector lever position face to selector lever contact springs -item 27- Secure connector with retainer -item 6- to frame -item 7- Insert fibre optic light guide and wiring to connector housing in the mountings on frame - Connecting and disconnecting connector 6. Retainer - Clip push in housing into frame -item 77. Frame - Carefully pry off in corners - Push in cover strip -item 4- Note position of printed circuits and wiring -item 5- When installing do not damage contact springs -item 27- for selector lever position display 8. Bolt, 7 Nm - For locating spring -item- 12 and plate -item 11- to frame 9. Shim Page 3235 If the specified value is not obtained: - Remove wiper arms and plenum chamber cover. Page 1808 S177 - Fuse -5- (30) in fuse bracket/battery S178 - Fuse -6- (30) In Fuse Bracket/Battery S178 - Fuse -6- (30) in fuse bracket/battery S179 - Fuse -7- (30) In Fuse Bracket/Battery Page 5021 1. Selector lever knob - Screw on and off together with gaiter 2. Boot - Separating from gear shift knob = Fig. 1 - Connect to gear shift knob before installing = Fig. 1 - Remove and install together with gear shift knob 3. Sleeve 4. Clamp - To secure gear shift knob on gear lever 5. Frame 6. Sound insulation Page 6274 - Clamp off suction hose with hose clamps 3094. - Open spring clip -3- and pull off suction hose with special tool VAS 5024. - Clamp off return hose with hose clamps 3094. - Remove banjo bolt -2-. - Seal pressure line/hose with a plastic bag or similar. - Remove hex bolts -1- and -2-. Page 2193 Camshaft Gear/Sprocket: Tools and Equipment Puller Claw for VW 2.0 Turbo; Accessory Arm AST Tool # T 40001-7 Puller Claw for VW 2.0 Turbo; Accessory Arm AST tool# T 40001-7 Puller Claw - Accessory Arm used in conjunction with T 40001 Puller and T 40001-6 Arm. (Not part of the T 40001 kit; order separately.) Applicable to: VW/Audi: 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT); Used to remove Camshaft Gear / Wheel. - Made in Germany - Contact AST for pricing - Applicable; VW/Audi 2.0L 4V Direct Injection Engine (BPY) (BPG) (BWT) - Thin finger on end of Claw to fit into the tight area behind the Cam Wheel Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 6265 1. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 2. Suction hose 3. Pressure hose 4. Pressure switch ^ Switches at 40 bar (580 psi) ^ Tighten to 15 Nm (11 ft. lbs.) 5. Seal ^ Always replace 6. Banjo bolt ^ 30 Nm (22 ft. lbs.) 7. Seal ^ Always replace 8. Suction hose ^ White or yellow ring must seat within retainer 9. Retainer 10. Hex bolt 11. Mounting bracket Pressure line and suction hose (1.8 liter engines with O9A transmission) Lighting - Brake Light Switch Installation Precaution Brake Light Switch: All Technical Service Bulletins Lighting - Brake Light Switch Installation Precaution Group: 46 Number: 04-01 Date: Feb. 17, 2004 Subject: New Style Brake Light Switch Requires Care During Installation to Prevent Damage to Switch Model(s): Golf, Jetta 1999 --> 2004 New Beetle 1998 --> 2004 Supersedes T.B. Group 46 Number 03-01 dated Nov. 7, 2003 Revised brake switch Part No: 1J0 945 511D may be damaged during installation if not properly installed. The revised switch Part No: 1J0 945 511D: ^ Currently supersedes brake switch Part Nos: 1J0 945 511A and 1J0 945 511B and 1J0 945 511C for the models listed (does not include Eurovan). ^ Part Nos. 1J0 945 511B , 511C, and 511D may be installed only once, if switch is removed, it must be replaced with a new switch. ^ Can only be tested in the installed position. ^ Contains internal switch(es) which can be damaged if not correctly installed and adjusted properly. CAUTION! DO NOT depress plunger prior to installation. Service If brake switch requires replacement: - Remove cover below instrument panel. - Disconnect connector from brake switch. - Identify Part No. suffix (A, B, C or D) of switch installed. - Remove switch using the appropriate procedure for the Part No. suffix. 1. Brake switch, Part No: 1J0 945 511A, removing: Page 2530 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 2420 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 2480 Note: To prevent damage to the condenser, refridgerant lines and hoses, be careful that the lines and hoses are not overstretched, creased or bent. - Unscrew retention strap(s) on refrigerant lines. - Remove condenser from radiator and fasten to lock carrier. Installing Installation is in reverse order, but note the following: - Fill with coolant,refer to Coolant - Service and Repair - Procedures See: Coolant/Service and Repair Page 3735 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) -G68Removing and Installing VSS -G68Special tools, testers and auxiliary items - Obtain radio code on vehicles with coded radio. - Switch ignition off and disconnect battery ground strap. - Remove battery. - Remove air cleaner. - Install support bar 10-222 A with legs 10-222 A/1 (adapter 10-222 N3 for 6-cyl. engine) and support engine/transmission in position. - Remove bracket for power steering pressure hose. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Front Axle Nut: Specifications Front Vehicles with 12-point nut Tighten 12-point nut to 200 Nm (147.5 ft lb) and then loosen 1/2 turn. Turn hub 180°. Tighten 12 point nut to 50 Nm (37 ft lb) plus an additional 60° turn. Vehicles with hex bolt Tighten hex bolt to 250 Nm (184.4 ft lb) and an additional 90° turn and then loosen 1/2 turn. Turn hub 180°. Then finally tighten to 250 Nm (184.4 ft lb) plus additional 90° turn. To tighten 12-point nut/hex bolt we recommend the angle measuring wrench VAG 1756. NOTE: If an angle measuring wrench is not available, then tighten 12-point nut using following method: - Lower vehicle until the wheels touch ground. - Tighten 12-point nut to 200 Nm (148 ft lb) and then loosen 1/2 turn (180°). - Tighten 12-point nut to 50 Nm (37 ft lb). Electrical Specifications Fuel Injector: Electrical Specifications Between Terminals 13.0 to 19.0 ohms Page 3861 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 263 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 5285 Installing and adjusting multi-function TR switch - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 61 - Screen displays strength of signal (LEVEL) in bar graph form (can be used for AM and FM). - Press mix button briefly again. ^ Screen indicates number of stations broadcasting close to frequency band of selected station. ^ As the number increases for [mp] and (adj], static and signal crossing will increase. To exit service mode: - Depress and hold the mix button or switch radio OFF then back ON Navigation units ^ No internal diagnosis functions. Continue to antenna lead diagnosis. Section 3 - Antenna Lead Diagnosis After initial radio diagnosis using internal service functions, use the following procedures: - Locate antenna lead/s from radio at system end-point, i.e. diversity box or antenna mast base. - Check for proper connection. (follow steps for your type of system). - For all systems, locate cable end-point at either diversity box or antenna mast base. - Disconnect cable from either diversity box or antenna mast base. - Carefully ground center wire in cable to chassis. If reception returns: ^ Cable and radio are ok. Diagram Information and Instructions Transmission Speed Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 2362 ^ Remove wires from sensor connector and clean connector housing. ^ Cut brown/white wire from sensor harness and tape back into harness (see above - Unused wiring, taping back to harness). Using light yellow splice connectors Part No: 111971941A: ^ Adding wire as necessary to reach sensor, splice appropriate wire with terminal on brown/white wire of overlay harness. ^ Insert terminal from overlay harness into appropriate cavity of sensor connector. ^ Install new wire with terminal on remaining factory harness wire using appropriate connectors/wires from the VAS 1978 kit. ^ Insert into appropriate cavity of sensor connector. ^ Reinstall connector on sensor. Fuel fuel gauge sensor overlay harness, preparing for Diesel vehicles Tip: Vehicles with TDI engines do not use an in-tank fuel pump. For vehicles with TDI engine, perform the following prior to installing harness: ^ Remove wire terminals from fuel pump harness connector -A- and discard connector. ^ Cut terminals from two large wires, fold and tape wires (Blue/red and brown at both ends of harness) back into harness using vinyl tape (see above - Unused wiring, taping back to harness). ^ Insert two small wires from overlay harness into appropriate cavities of two wire fuel gauge sensor connector -B- (provided in kit). Fuel pump / fuel gauge sensor overlay harness, preparing factory harness ^ Disconnect fuel pump / fuel gauge sensor connector including cable guiding. ^ Loosen fuel pump / fuel gauge sensor wiring harness from its attachment point below the seat belt on passenger side "B" pillar. ^ Remove tape covering from wiring harness, starting where fuel pump harness joins the main harness (arrow) and working forward to a point approx. 5 cm (2 inches) in front of the attachment point (loosened earlier at "B" pillar). Page 2918 Vehicle Speed Sensor: Testing and Inspection With Generic Scan Tool Checking Speed Signal Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Battery voltage must be at least 11.5 volts. - Speedometer -G21- must be OK. Test sequence NOTE: To test speed signal, vehicle must be driven. Doing this requires a second person. WARNING: Secure Scan Tool (ST) on the rear seat and have operated from there by second technician. - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 13: Vehicle speed". - Perform a road test, and have the 2nd person observe the indication on the display. - Check specified value of the vehicle speed: - End diagnosis and switch ignition off. If no speed is indicated: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - To measure voltage, connect multimeter between sockets 2 (Ground -GND-) +54 (speed signal) of test box. - Raise vehicle at front left. - Switch ignition on. - Rotate front wheel, and observe voltage indicated while doing so. Specified value: 0.0 to at least 4.0 V, fluctuating NOTE: The right front wheel must not turn during this, hold it steady if necessary. 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 5828 Battery: Locations A - Battery A - Battery - engine compartment, left side - under battery cover Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3548 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1165 Camshaft Position Sensor: Service and Repair 1 O-ring Always replace 2 Camshaft Position (CMP) sensor -G40- To remove, unclip cable guide (item -5-) for ignition coil. Sensor and harness connector contacts are gold- plated 3 Mounting bolt 10 Nm (7 ft lb) 4 Harness connector Black, 3-pin Sensor and harness connector contacts are gold-plated Page 99 - Antenna cables - double DIN (Premium VI) radio. - Antenna cables - Phaeton 2004 > 2006 - Antenna cables - Satellite radio (Hard top vehicles) Page 3905 - Check wiring between test box and fuel injector 2-pin harness connectors for open circuit according to wiring diagram. - Injector 1: terminal -2- + socket 96 - Injector 2: terminal -2- + socket 112 - Injector 3: terminal -2- + socket 88 - Injector 4: terminal -2- + socket 113 - Injector 5: terminal -2- + socket 97 - Injector 6: terminal -2- + socket 89 - Wire resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value: infinity ohms If there is no malfunction in the wiring, and the resistance measurement values are OK: - Replace Engine Control Module (ECM). With Generic Scan Tool Check Fuel Injectors Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1527 voltage test lamp - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of fuel injectors (Cylinder 1 Fuel Injector -N30- to Cylinder 4 Fuel Injector -N33-, Cylinder 5 Fuel Injector -N83-, Cylinder 6 Fuel Injector -N84-) must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. Page 2328 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 227 2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting of flowcharts. Condition Page 4646 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 4231 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 4640 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6522 VW/Audi axle nut set. Contains:6500-14, 6500-17, 6500 X-30, and 6500 X-32. - 14mm allen for VW Passat 1996-2001, Audi A4; front and rear axle bolts (AWD) - 17mm allen for 1998-2005 VW Passat, 1999-2004 Audi A6, 2002-2005 Audi A4; front and rear axle bolts (AWD) - 30mm 12 point socket for mid 1999-2005 VW Golf, Jetta, Cabrio, and Beetle; front axle nut - 32mm 12 point socket with a 3/4" drive, VW Touareg; front and rear axle nuts Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: 6500-14 - 14mm Allen Socket Page 1478 Part 2 Page 3919 37 - Non - Return Valve. - Black valve side faces T-pieces connection fuel pressure regulator / intake manifold upper section. 38 - 2-Pin Harness Connector. Black. - For Secondary Air Injection (AIR) solenoid valve - N112 -. 39 - Secondary Air Injection (AIR) Solenoid Valve - N112 -. Secondary air system. 40 - Intake Manifold Change - Over Valve - N156 -. Check. 41 - 2-Pin Harness Connector. Black. - Intake Manifold change-over valve - N156 -. Heated Seat Control Module/Regulator, Removing and Installing Hazard Warning Switch: Service and Repair Heated Seat Control Module/Regulator, Removing and Installing Switches In Instrument Panel, Removing And Installing Switches consists of a switch housing and trim plate with relevant symbol. The trim plate is clipped onto the switch housing. If the trim is released instead of the switch during removal, the trim must be re-clipped onto the switch housing afterwards. Remove switches with connected wiring from instrument panel opening prior to disconnecting electrical connection on rear of switch. If necessary, temporarily remove switch to the left of of the switch to be removed/replaced to allow sufficient access to the wiring. NOTE: Switch blank-out covers (where applicable) are removed in the same manner as switches. CAUTION! - Be careful not to damage instrument panel when removing switch. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. Heated Seat Control Module/regulator, Removing And Installing Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 4582 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Page 5441 ^ Disconnect connector -1- of Mass Air Flow MAF sensor from air filter tube ^ Remove bolts -2- at air filter -3- and move filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. ^ Remove as much brake fluid as possible from brake fluid reservoir using a brake bleeder bottle. ^ Insert brake pedal depressor VAG 1869/2 or equivalent. ^ Activate brake pedal booster with brake pedal depressor. ^ Connect bleeder bottle hose to bleed screw of left front brake caliper and open bleed screw. ^ Close left front bleed screw. ^ Release ABS control module connector (arrow-1-) and remove (arrow-2-). ^ Place plastic covering under control module and hydraulic unit. Do not use rags. Note: Do not let brake fluid enter electrical connectors. ^ Disconnect brake lines from hydraulic unit to brake master cylinder (arrows) and suspend with wire. ^ Disconnect remaining brake lines from hydraulic unit. ^ Seal brake lines and threaded holes (arrows) using plugs from repair kit, Part No. 1 HO 698 311 A. Page 3314 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Page 5295 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 205 Part 2 Page 4579 Test Step 10 - 11 Page 5373 Page 1254 Oxygen Sensor: Testing and Inspection Oxygen Sensor and O2 Sensor Control Before TWC, Checking Sensor and Control Check Oxygen Sensor and Oxygen Sensor Control (Before Three Way Catalytic Converter (TWC)), Checking NOTE: Only gold plated contacts must be used to repair contacts 3 and 4 in the oxygen sensors harness connectors. Special tools and equipment - VAG1551/VAG1552 with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - Min. coolant temp. 85 °C See display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -3- and -0- to input display group number 30 and press -Q- button to confirm input. Indicated on display: (1-2 = display fields) Read Measuring Value Block 30 -> 12 Page 471 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 3959 Fuel Gauge Sender: Service and Repair Fuel Level Sensor, Removing And Installing Removing - Remove fuel delivery module. - Unlock and remove attachment plugs for lines -3- and -4-. - Lift tabs -1 - and -2- with a screwdriver and remove fuel level sensor from below -arrows-. Installing - Insert fuel level sensor into delivery module guides and press upwards until they click into position. - Install fuel delivery module. Page 2800 Display Group 4 Evaluating display group 4, display field 4-Intake air temperature Page 1147 - Check air mass drawn in in display field 4. Display Group 002 - If value is as specified, DTC memory has recorded a malfunction relating to Mass Air Flow (MAF) sensor, test signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Evaluating display group 2, display field 4 - Air mass drawn in Testing power supply to Mass Air Flow (MAF) sensor -G70- Page 321 Electronic Brake Control Module: Diagrams ABS Control Module (w/EDL) Page 3507 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Page 6013 Fuse arrangements in fuse holder, instrument panel left Page 1258 Learning prerequisites for part load: - Coolant temperature min. 75 °C - Intake air temperature max. 90 °C If the specified value is obtained: - Change to display group 33 as follows: - VAG1551: Press button 3 - VAG1552: Press button up arrow Indicated on display: (1-2 = display fields) Read Measuring Value Block 33 -> 12 - Observe Oxygen Sensor (O2S) control in display field 1. If the specified value is obtained: Display Group 033 If the specified value is obtained: Sensor For Transverse Acceleration (Vehicles With ESP) Lateral Accelerometer: Locations Sensor For Transverse Acceleration (Vehicles With ESP) G200 - Sensor for transverse acceleration (vehicles with ESP) Page 3413 - Check voltage supply of Engine Control Module (ECM). See: Testing and Inspection/Component Tests and General Diagnostics/Engine Control Module (ECM) Voltage Supply, Checking - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes With Manufacturer's Scan Tool Throttle Valve Control Module, Checking Components of the throttle valve control module -J338-: - Throttle drive (power accelerator actuation) -G186- Angle sensor -1 - for for throttle drive (power accelerator actuation) -G187- Angle sensor -2- for for throttle drive (power accelerator actuation) -G188NOTE: - If the throttle valve control module is replaced, the new control module must be matched to the Engine Control Module (ECM). Refer to "Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation", See: Engine Control Module/Testing and Inspection - On vehicles with an automatic transmission, the Transmission Control Module (TCM) must also be adapted. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Throttle valve not damaged or dirty. - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3 NOTE: Only gold plated contacts can be used to repair the contacts in the connector for the throttle valve control module. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-1-6- and -2- to input display group number 62 (062) and press -Q- button to confirm input. - Check angle sensor -1- for for throttle drive (power accelerator actuation) -G187- on idle speed stop in display field 1. - Check angle sensor -2- for for throttle drive (power accelerator actuation) -G188- on idle speed stop in display field 2. Page 5050 Shifter M/T: Service and Repair Shift Lever Servicing 5 Speed Manual 02J Gear Lever, Servicing Note: Lubricate all mountings and sliding surfaces with MoS2 grease 1. Gate selector cable - On gate selector bracket 2. Gear selector cable - On gear lever 3. Gate selector bracket 4. Bolt, 15 Nm (11 ft. lbs.) - For fulcrum pin to mounting plate 5. Fulcrum pin 6. Mounting plate 7. Nut, 20 Nm (15 ft. lbs.) - For mounting plate to gear lever housing - Self-locking - Always replace 8. Cap Page 3798 - Fuse no. 43 must be OK - The temperature of the coolant must be at least 85 °C See display group 04, field 3 Functional test - Connect VAG 1551 (or VAG 1552) scan tool. Leave engine running and select engine control module using "address word" 01. Indicated on display: Rapid Data Transfer HELP Select Function XX - Press keys "0" and "8" for function "Read Measuring Value Block" and acknowledge entry by pressing "Q." Indicated on display: Read Measuring Value Block Enter Display Group No. XXX - Press keys "0", "7" and "0" for display group 70 and acknowledge entry by pressing "Q." Indicated on display (1-4 = display fields). Read Measuring Value Block 70 -> 1234 - Press "4" for function "basic setting." Diagnosis of evaporative emissions system is started. NOTE: No load may be produced during this diagnosis. Otherwise the diagnosis will be stopped and can only be started again after applying the accelerator. Indicated on display (1-4 = display fields). System in basic setting 70 -> 1234 - Let engine idle until specification "TEV OK" is displayed in field 4. If the diagnosis is started by the engine control module, the display in field 4 will jump from "Test OFF" to "Test ON". NOTE: If the display switches from "Test ON" to "Test OFF" during the test, the test can be repeated by a brief application of the accelerator. Outside Air Temperature Sensor -G17- (Where Applicable) Ambient Temperature Sensor / Switch HVAC: Locations Outside Air Temperature Sensor -G17(Where Applicable) Outside Air Temperature Sensor -G17- (where Applicable) Sensor -arrow- located on left of front bumper behind outer air grill. Unclip air grill to remove sender. Page 2346 Coolant: Service and Repair Coolant, draining and filling Special tools, equipment, test and inspection devices; required accessories - VAG 1306 Drip tray for VAG 1202A - VAG 1921 Hose clip pliers - Hydrometer Draining - Open coolant recovery bottle cap. - Remove damping pan. - Unscrew drain plug -arrow- from radiator return to drain coolant from radiator. Page 1359 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V Page 149 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1981 - Measure resistance between terminals of the respective valve for camshaft adjustment. Specified value: 10...18 Ohms If specified value is not obtained: - Replace control housing for camshaft adjustment, item3. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 2-pin connector to Engine Control Module (ECM) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to B+ and Ground (GND). Specified value: Infinity Ohms - Check wire between 2-pin connector terminal 1 and Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit according to wiring diagram Wire resistance: max: 1.5 Ohms If resistances and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 451 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 2917 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Connect multimeter to measure voltage between test box sockets -2- + -54-. - Switch ignition on. - Lift vehicle at left-front. - Rotate front wheel and observe voltage display. Specified value: between 0 and at least 4 Volts, fluctuating. NOTE: If necessary, hold the right-front wheel to prevent it from turning. If the display does not fluctuate: - Check wiring to speedometer/speedometer sensor. - Check DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 6095 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4751 Torque Converter: Application and ID 5 Speed Automatic 09A There are various torque converters. They are identified by the code letters (arrow). Transmission/torque converter allocation Torque converter code letters (Transmission installed) Page 3296 - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Initiating and Checking Control Module Versions Data Bus On Board Diagnostic Interface, On Board Diagnostic (OBD), Initiating, Checking Control Module Versions Test requirements: - All fuses OK according to wiring diagram - Voltage supply OK (at least 11.5 V). - Scan Tool VAG 1551 or VAG 1552 connected. NOTE: - Connecting Scan Tool. Refer to "Scan Tool Testing/Scan Tool Connecting and Initial Checks" - The following description applies only to Scan Tool VAG 1551. - Switch on ignition. - Switch on printer with the PRINT button (indicator lamp in button lights up). - Press button -1- to select operating mode 1 "Rapid data transfer". Indicated on display: Rapid data transfer HELP Input address word XX - Press buttons -1- and -9- to input "Gateway" address word 19. Indicated on display: Rapid data transfer Q 19 - Diagnostic Interface for Data Bus - Press -Q- button to confirm input. Indicated on display: Rapid data transfer Q Tester sends address word 19 Indicated on display (example only): 6N0909901 Gateway K <-> CAN 0001 Coding 00007 WSC 00000 Top line: Part No. of control module System designation (Gateway K <-> CAN) 1) Software level Bottom line: Coding 2) Workshop number 1) The Data Bus On Board Diagnostic Interface -J533- in instrument cluster is referred to in the OBD program as "Gateway". 2) Dependant on the control modules connected to the CAN Bus network. - Press -> button. With Manufacturer's Scan Tool Air Injection Pump: Testing and Inspection With Manufacturer's Scan Tool Motor for secondary air injection pump, checking Special tools, equipment, test and inspection devices; required accessories VAG 1527 B diode test lamp - VAG 1594 A auxiliary measuring tool set - VAG 1598/31 test box Test condition Page 2608 Heat Shield: Service and Repair For further information regarding this component please refer to Exhaust Systems; Service and Repair. Brakes - Master Cylinder/ABS Pressure Testing Adapter Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins Brakes - Master Cylinder/ABS Pressure Testing Adapter Condition Master Cylinder / ABS, Adaptor for Checking Pressure Pressure adaptor VAG 1310/26 allows the use of VAG 1310 A to check for hydraulic pressure loss at either the master cylinder or ABS control unit. Before replacing the ABS unit due to an incorrect pressure reading when performing Leak Test, check brake fluid pressure at the master cylinder and ABS unit as follows: 47 06 01 Aug. 28, 2006 2002320 Supersedes T.B. Group 47 number 01-01 dated January 4, 2001 due to updated information. Technical Background Introduction of adaptor to allow pressure testing of brake hydraulic system. Production Solution No production change required. Service Pressure Leak Test Obtain special tools: - VAG 1310/26 Pressure Adaptor - VAG 1310 A Brake Pressure Gauge Use VAG 1310/26 with VAG 1310 A to measure hydraulic brake pressure at master cylinder and ABS unit as follows: - Remove brake lines at either master cylinder port (A or B). Install VAG 1310/26 at port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". Brake fluid pressure can also be checked at the ABS unit: - Disconnect brake lines from ABS unit to disc brake calipers (1-4), one at a time. Page 3283 - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. - The -> button is used for advancing through the program sequence. Page 533 Tip: Battery voltage must be substantiated by a Midtronics M0R340V printout. Printout must be attached to the repair order. If ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation. - With battery fully charged: - Connect the VAS 5051/5052 Diagnostic tool. - Switch ignition ON. - Select "Vehicle Self Diagnosis". - Interrogate and erase DTC memory. - Perform throttle adaptation (see appropriate Repair Manual and Repair Group 23 or 24). - Start engine and allow to run briefly, then switch engine OFF. - Repeat above step (Start/Shut OFF) 5 times. - Check DTC memory again. If MIL does not illuminate and DTC has not returned: ^ A low battery condition most likely caused the DTC to be stored. - Set readiness code. If MIL illuminates or DTC has been stored again, perform the following: - Replace ECM (see appropriate Repair Manual and Repair Group 23 or 24). - Set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, use the table. Page 557 - The respective fuses of Motronic Engine Control Module (ECM) - J220- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Generator (GEN) must be OK, checking. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. Test sequence - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Checking voltage supply terminal 30 - Measure voltage supply between sockets 1 + 62 and 2 + 62 of test box. Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram: - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking voltage supply terminal 15 - Measure voltage supply between sockets 1 + 3 and 2 + 3 of test box. - Switch ignition on. - Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 4564 46 - Solenoid valve 8 -N281- 47 - Vacant 48 - Solenoid valve 1 -N8849 - Solenoid valve 2 -N8950 - Solenoid valve 5 -N9251 - Solenoid valve 9 -N28252 - Vacant 53 - Vacant 54 - Park/neutral signal to Park/Neutral position (PNP) relay -J22655 - Vacant 56 - Vacant 57 - Vacant 58 - Vacant 59 - Vacant 60 - Gate switch for Tiptronic gate 61 - Tiptronic change up 62 - Tiptronic change down 63 - Road speed (engine output) 64 - Ground return wire (to valve diagnosis) 65 - Vacant 66 - Solenoid valve 6 supply voltage -N9367 - Vacant 68 - Supply voltage (terminal 15) Test table Page 6406 Tightening torque: Bearing bracket to rear axle 80 Nm (59 ft lb) Use new nuts and bolts! Page 5547 Brake Rotor/Disc: Specifications Front Brakes With FS II Caliper Thickness ............................................................................................................................................ ............................................ 22 mm (0.866 in.) Wear Limit ................................................................. ..................................................................................................................... 19 mm (0.748 in.) With FN 3 Caliper Thickness ............................................................................................................................................ ............................................ 25 mm (0.984 in.) Wear Limit ................................................................. ..................................................................................................................... 22 mm (0.866 in.) Rear Brakes Solid Rotor Thickness ............................................................................................................................................ .............................................. 9 mm (0.354 in.) Wear Limit ................................................................. ....................................................................................................................... 7 mm (0.276 in.) Vented Rotor Thickness ............................................................................................................................................ ............................................ 22 mm (0.866 in.) Wear Limit ................................................................. ..................................................................................................................... 20 mm (0.787 in.) Page 676 Power Window Control Module: Electrical Diagrams For information regarding diagrams for the Power Window Control Modules, please refer to the Comfort System Diagrams. Left Front Door Right Front Door Left Rear Door Right Rear Door With Manufacturer's Scan Tool A/C Signal: Testing and Inspection With Manufacturer's Scan Tool Signal From/to A/C Compressor, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Fuses 5, 10 and 29 OK - Air conditioner functioning OK - Air conditioner switched off - No DTCs stored in DTC memory. - All electrical consumers (e.g. lights and window defroster) switched off - Battery (B+) voltage at least 11.5 V - Vehicle at room temperature (warmer than + 15 °C). Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -5- and -0- to input display group number 50 (050) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 50 -> 1234 - Check specified values for air conditioner (display fields 3 and 4). Page 1560 Alignment: Testing and Inspection Wheel alignment, checking General It is always necessary to check alignment of all four wheels to ensure correct driving characteristics. Otherwise correct vehicle performance is not guaranteed and an off center steering wheel may exist. NOTE: ^ Perform vehicle alignment only after 1000 - 2000 km (600 - 1200 miles) to allow suspension time to settled. ^ Otherwise precise settings are difficult to reach. Steering wheel and steering column are marked. A- Line on steering wheel B- Punch mark on steering column These positions must not be changed! Steering rack center position is not ensured otherwise. Steering columns supplied as spare parts do not have a center punch mark. These spare part steering columns must be marked after vehicle alignment and test drive. Tightening torque: Multi-point socket-head bolt 50 Nm (37 ft. lbs.). Wheel alignment is necessary if any of the following are true. ^ Vehicle is not tracking properly ^ Damage from an accident. ^ Tire wear on one side. Page 95 Section 2 - Radio antenna system diagnosis through radio unit Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit. All models except Touareg and Phaeton: - Select AM or FM. - Press and hold the mix button (black arrow). - Screen will appear that shows "Service Test mode" (white arrow). - Press mix button briefly. ^ Test one indicates current antenna status, i.e. ON or OFF (arrow). - Press mix button briefly again. Page 1727 Warranty Required Parts and Tools Page 6264 1. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 2. Suction hose 3. Pressure hose 4. Banjo bolt ^ 30 Nm (22 ft. lbs.) 5. Seal ^ Always replace 6. Suction hose ^ White or yellow ring must seat within retainer 7. Retainer 8. Hex nut 9. Mounting bracket Pressure line and suction hose (1.8 liter engines with A/C) Locations Power Protection Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 5726 Volkswagen Canada, Inc. Page 5439 B Primary piston circuit Page 1926 6500 X-32 - 32mm, 12-Pt. Socket Selector Mechanism Removing and Installing Shifter M/T: Service and Repair Selector Mechanism Removing and Installing 5 Speed Manual 02J Selector mechanism, removing and installing Removing Selector mechanism up to 12.00 - Pry gate selector cable -A- and gear selector cable -B- off transmission using an open jaw spanner. 1 = 13 mm open jaw spanner, commercially available Selector mechanism from 01.01 - Remove securing clip -3- for gear selector cable from gear selector lever -1-. - Remove securing clip -4- for gate selector cable from relay lever -2-. - Lever gate selector cable and gear selector cable off pin (arrows). Continued for all selector mechanism Page 1546 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 4190 - Perform On Board Diagnostic (OBD). - Initiate basic setting. Page 3790 Display Fields If the indicator does not behave as described: - Press - button. - Check DTC memory. If the indicator behaves as described: Release brake pedal. If "Cat B1 OK" is displayed in field 4: Check DTC memory. - Read-out readiness code. - If fault memory was erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. Diagram Information and Instructions Brake Light Switch: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5057 12. Gasket - Between selector cables and gear lever housing 13. Selector housing 14. Gasket - Self adhesive - Bond underneath gear lever housing 15. Cover plate 16. Hex combi bolt, 25 Nm Fig. 1 Separating cover from gear shift knob and assembling to gear shift knob - Turn boot inside out. - Carefully pry segment with a screwdriver in direction of arrow and simultaneously pull gear shift knob out. Installation is carried out in the reverse sequence. Also, note the following: Insert gear shift knob in cover. - Push sleeve onto gear shift knob and engage. - Install gear shift knob and boot together. Page 5165 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 476 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 3658 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 1627 NOTE: The camshafts do not have timing marks, special tool 3268 is required to time camshafts. Please see Timing Chain / Service and Repair for complete procedures to set/adjust the camshaft, intermediate shaft and Crankshaft timing alignment. See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Chain/Service and Repair. Page 168 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 5436 - Install VAG 1310/26 at each port. - Install VAG 1310 A onto VAG 1310/26. - Perform brake pressure leak test, see Repair Manual Group 47 "Pressure leak test". NOTE: Once the brake pressure leak test has been completed, the hydraulic brake system MUST be purged of any entrained air. See Repair Manual Group 47, Brake System Bleeding. Warranty Information only. Required Parts and Tools No Special Parts required. Always see ETKA for the latest part(s) information. Page 5631 ^ Remove bolts from bracket for hydraulic unit (arrows). ^ Remove hydraulic unit with control module. ABS control module, removing from hydraulic unit ^ Disconnect electrical connector for hydraulic pump motor from control module. ^ Remove bolts (arrows) from control module and remove control module. Notes: ^ When removing the control module make sure that the hydraulic unit valve dome does not contact the control module solenoid valves. ^ Cover the control module magnet coils with a plastic cover. Do not use rags. ^ After separating the control module and hydraulic unit use transportation protection for the valve dome. Installing Notes: ^ Only remove the sealing plugs on the new hydraulic unit just before installing the corresponding brake line. ^ If the sealing plugs are removed from the hydraulic unit too early, brake fluid can escape. It can then no longer be guaranteed the unit is sufficiently filled or adequately bled. ^ When assembling the control module and hydraulic unit, be sure that the hydraulic unit valve dome does not come in contact with the control module solenoid valves. ^ Using new bolts, install control module to hydraulic unit. Do not tighten more than maximum 4 Nm (35 inch lbs.). Page 2815 Display Group 028: Ignition, Knock Sensor If the specification is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the specifications are not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Knock Sensor (KS) 1 -G61- Installation Position Shifter M/T: Diagrams Installation Position 5 Speed Manual 02J Gear Selector Mechanism, Installation Position A -Gear change cable B -Gate selector cable C -Heat shield Remove before removing gear selector mechanism. Arrow -A- gear selection movement Arrow -B- gate selection movement 1. Gear selector lever 2. Relay lever Page 6496 11. Ball joint ^ Checking; Refer to Ball joint; Testing and Inspection 12. Self-locking nut, 45 Nm (33 ft lb) ^ Always replace 13. Shield plate 14. Hex bolt, 10 Nm (89 in lb) 15. Hex bolt ^ For special model "Golf GTI 132 kW" ^ Always replace 16. Self-locking 12-point nut ^ Always replace 17. Phillips screw, 4 Nm (35 in lb) 18. Ventilated brake disc 19. Wheel hub with speed sensor rotor ^ Rotor is welded to wheel hub 20. Circlip ^ Make sure seated correctly 21. Wheel bearing ^ Pressing wheel bearing out of wheel bearing housing ^ Replace, as it is destroyed during pressing out ^ Pressing wheel bearing into wheel bearing housing 22. Wheel bearing housing For vehicles: ^ With gasoline engines from 110 kW (147.5 Hp) Pressing wheel hub out of wheel bearing housing 4 Speed 01M Transmission Drain Plug: Specifications 4 Speed 01M Transmission 4 Speed 01M Transmission 1 Level Plug (with Overflow Line Tube)................................................................................................ .............................................................. 15 Nm 2 Fill Plug (with protective cap) Note: Always replace protective caps without spring retainers. The cap secures the plug. Service and Repair Timing Component Alignment Marks: Service and Repair Please see Timing Chain / Service and Repair for complete procedures to set/adjust the camshaft, intermediate shaft and Crankshaft timing alignment. See: Timing Chain/Service and Repair. Page 3519 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. Audio System - Poor Radio Reception Technical Service Bulletin # 9105-01 Date: 050502 Audio System - Poor Radio Reception Group: 91 Number: 05-01 Date: May 2, 2005 Subject: Radio, Reception Diagnosis Model(s): All with Premium V and VI Radio 1998 > 2006 Condition Poor radio reception. Service Procedure For concerns of poor radio reception: - Use the following as a guide for trouble shooting. Tip: This Technical Bulletin is divided into four sections: ^ Section 1: Includes antenna systems by vehicle. ^ Section 2: Includes radio antenna system diagnosis procedures for AM/FM concerns using internal radio diagnostics. ^ Section 3: Includes antenna lead diagnosis. ^ Section 4: Antenna cables Tip: ^ Perceived reception issues may be a result of environmental factors. ^ Reception may be diminished in certain areas due to power wires, buildings and/or overpasses. ^ Aftermarket window tint may interfere with reception. ^ In cases that are questionable, locate identical vehicle and verify concern (if the like vehicle is same, condition may be normal). Section 1 - Antenna systems by vehicle Tip: For more detail see Repair Manual Group 91- Communication of the vehicle you are working on. Passat (W8 only) Mechanical Specifications Engine Oil Pressure: Mechanical Specifications Oil pressure at idle at least 2.0 bar at 2000 rpm at least 2.0 bar not to exceed 7.0 bar Page 1355 1 O-ring 2 Camshaft Position Sensor -G40 3 Mounting Bolt - 10Nm (22 ft. lbs.) 4 Harness Connector (Black, 3-pin) 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module: Locations 4 Speed Automatic 01M & 5 Speed Automatic 09A Engine Control Module location The control module is located in plenum chamber. Page 5885 - Tighten battery terminal clamp securing screw to 6 Nm (53 in.lb). Only after the plus terminal securing clamp and the fuse holder have been installed may the Ground (GND) strap be secured to the negative terminal. - Tighten terminal clamp securing screw to 6 Nm (53 in.lb). NOTES: When the battery has been reconnected, check operation of electrical equipment (radio, clock and convenience electrics etc.). - For OBD II vehicles, the readiness code for the Engine Control Module (ECM) must be re-generated after the battery has been disconnected. - After installing, check if battery is seated securely. The following dangers exist with a loosely installed battery: Shortened service life due to damage from vibration. - The cells in the battery will be damaged if the battery is not secured correctly. - Damage to battery housing by clamping bracket (possibility of acid leaking, therefore subsequent higher costs). - Poor crash safety Batteries with central gas venting There are two types of batteries with central gas vents: Batteries with a hose on central gas vent. - Batteries without a hose on central gas vent. It is absolutely necessary to use original sealing plugs in the battery screwed openings to guarantee the battery is sealed correctly. Use original sealing plugs of same construction if lost or damaged. The sealing plugs must be installed with an O-ring. Functional notes for central venting: - Batteries of the latest generation are equipped with a central venting system with anti-flash protection. - The anti-flash protection consists of a small round fiberglass mat with a diameter of approx. 15 mm and a thickness of 2 mm. It functions similar to a valve to allow the gasses that form in the battery to vent. - The gasses that form while charging can vent centrally through an opening on the upper side of the cover The anti-flash protection is also installed at this point, which prevents ignition of the flammable gasses in the battery. Page 6434 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber/Spring, Removing and Installing Special tools and equipment ^ VAG 1752 Strut holder ^ VAG 1752/3 Strut adaptor ^ VAG 1752/9 adaptor Spring, removing Position spring holder-1-. - Compress coil spring enough to remove. - Remove spring. 1. VAG 1752/1 Strut spring tool 2. VAG 1752/9 adaptor 3. VAG 1752/3 Strut adaptor Removing spring Page 6404 Control Arm Bushing: Service and Repair Bonded Rubber Brushings, Removing and Installing Special tools and equipment ^ 3301 Assembly tool ^ 3346 Assembly tool ^ 3416/1 Press piece ^ 3416/2 Press piece ^ 3416/3 Support tube Removing - Unclip brake cable (arrows). - Remove clips -2- both sides. - Remove bolts -1 - on rear axle bearing bracket, both sides. Specifications Idle Speed: Specifications Not adjustable 680 to 720 rpm Body - Sunroof Malfunctions or is Inoperative Central Control Module: Customer Interest Body - Sunroof Malfunctions or is Inoperative 60 07 06 June 19, 2007 Page 3295 - Connect VAS 5051/1 or VAS 5051/3 diagnostic wire to Data Link Connector (DLC) - Switch on ignition. Select operating mode, vehicle system and function: - Press "Vehicle Self-Diagnosis" selection on display. - Select the vehicle system to be tested on display (touch screen). - Select the desired function on display. Display will indicate the control module identification and the coding. Display will indicate all relevant diagnostic functions. NOTE: - Display fields in functions 04 (Basic setting) and 08 (Read Measuring Value Block) are listed from top to bottom. - The following test sequences are described for the VAG 1551 Scan Tool (ST). VAG 1551, connecting Test requirements: - All fuses OK according to wiring diagram. - Battery voltage must be at least 11.5 volts. - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. - The -> button is used for advancing through the program sequence. Page 1346 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 3747 If the motor starts, it will be possible to feel a vacuum at the secondary air valve inlet nozzles. If no vacuum can be detected: Switch ignition off. - Remove 2-pin connector from secondary air valve -1-. - Connect VAG 1527 diode test lamp to disconnected attachment plug using auxiliary cables from VAG 1594. If the LED illuminates (power supply OK): Turn off ignition. - Replace secondary air valve -N112-. If the LED does not illuminate: Clip on 2-terminal attachment plug. - Start the control element diagnosis and trigger the secondary air valve N112-. - Check DTC memory. - Read-out readiness code. - If fault memory was erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. With Generic Scan Tool Secondary Air Injection (AIR) Valve, Checking Solenoid valve is closed when no voltage is present. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Secondary Air Injection (AIR) Solenoid Valve -N112- must be OK. - Ignition switched off. Test sequence Vehicles with engine code AFP Page 5818 ERROR: undefined OFFENDING COMMAND: f'~ STACK: Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) Switch - above clutch pedal - above clutch vacuum vent valve -F36- Page 5629 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Required special tools and equipment ^ VAG 1331 Torque wrench or equivalent ^ VAG 1410 Torque wrench or equivalent ^ VAG 1869/2 Brake pedal depressor or equivalent Component location: The ABS control module is bolted together with the hydraulic unit and is located in the engine compartment, left side. CAUTION! Brake lines in file area of file hydraulic unit should not be bent! Removing ^ For vehicles with a coded radio, obtain code. ^ Disconnect battery. Page 672 Part 2 Page 5299 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Service and Repair Engine Accessory Bracket: Service and Repair Special tools required - Torque wrench (5 - 50 Nm) NOTE: The compressor bracket and related components can be removed and installed without discharging the refrigerant circuit. 1 - Bracket for generator and compressor Removing: - Remove ribbed belt. - Remove compressor -8- and generator - Installing: First install bolts -3- and -11- Replacing: Also remove bracket for power steering pump - Remove bracket from engine block. 2 - Washer 3 - Bolt M8x28 25 Nm (18 ft lb) 4 - Allen head bolt M8x30 25 Nm (18 ft lb) 5 - Allen head bolt M8x38 25 Nm (18 ft lb) 6 - Allen head bolt M8x30 25 Nm (18 ft lb) 7 - Refrigerant hoses 8 - Compressor With A/C clutch -N259 - Ribbed belt 10 - Bolt M10x112 45 Nm (33 ft lb) 11 - Bolt M8x20 25 Nm (18 ft lb) 12 - Washer Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 3478 Engine Control Module: Testing and Inspection Engine Control Module (ECM) Voltage Supply, Checking With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuses 10 and 29 OK - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Generator OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 Engine - Rattling Noise On Start Up (Normal Condition) Variable Valve Timing Actuator: Technical Service Bulletins Engine - Rattling Noise On Start Up (Normal Condition) Condition Camshaft Chain Tensioner(s) or Camshaft Adjuster(s), Rattle or Knocking Noise 15 06 01 Oct. 24, 2006 2012988 Technical Background The camshaft adjustment is hydraulically actuated and controlled by the engine oil pressure. If the vehicle has been sitting, with the engine turned off for a period of time, the oil accumulation inside the camshaft adjusters partially bleeds off and the oil flows back into the oil sump. To ensure an efficient camshaft adjustment after an engine cold start, the oil pressure inside the camshaft adjusters must be built up as quickly as possible. During this time a slight rattle or knocking noise may be audible. This noise is normal at engine start and will last until the oil pressure is fully reinstated. Production Solution No production change required. Service DO NOT replace the Camshaft Tensioner(s) or Camshaft Adjuster(s) for the noise concern as described above. Tip: Replacing the Camshaft Tensioner(s) or Camshaft Adjuster(s) will not eliminate this noise. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Always see ETKA for the latest part(s) information. Page 2888 Transmission Position Switch/Sensor: Locations Multi-Function Transmission Range (TR) Switch F125 - Multi-function Transmission Range (TR) switch Page 5013 16. 1st/2nd selector fork - With selector segments refer to Fig. 5 17. Selector segment - Identification refer to Fig. 1 - After installing the circlip the segment must rotate freely 18. Circlip 19. Support for reverse gear selector fork 20. Reverse gear selector fork 21. Spring 22. Domed sliding piece Fig. 1 Identifying selector segments Dimension -a- 1. 1st and 2nd gear selector segments = 12.1 mm 2. 3rd and 4th gear selector segments = 7.7 mm 3. 5th gear selector segments = 12.1 mm Fig.2 Installing circlip Press circlip into selector segment groove with socket. Note: After installing the circlip the selector segment must rotate freely. A - Socket driver, 10 mm B - Jaw protectors Page 4409 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 5961 - Pull off plastic cap -1- from solenoid. - Remove nut (13 Nm) at solenoid terminal 30 and remove cable -1-. - Disconnect electrical connection at starter terminal 50 -2-. Page 5586 Special Tools: Section A Section A - Check ABS Control Module Part Number ^ Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column ^ Switch ignition to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics." ^ Read control module part number and code located in the upper right corner of the screen ^ If ABS control unit part number is 1C0 907 379 C, press <-- button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B ^ If ABS control unit part number is not 1C0 907 379 C no further work is required, press <-- button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code ^ Drive vehicle into hoist area ^ Raise vehicle on hoist Page 2163 4 - 10 Nm . 5 - 25 Nm . 6 - Vacuum Connection From Leak Detection Pump (LDP) -V144-. - EVAP System. 7 - Vacuum Connection From fuel pressure regulator / non-return valve T- piece. 8 - Vacuum Connection From brake servo. 9 - Vacuum Connection From crankcase breather / Evaporative Emissions (EVAP) canister purge regulator valve -N80T-piece connecting hose. 10 - Throttle Valve Control Module -J338-. Checking. Page 3233 Engine Control Module: Testing and Inspection Engine Control Module (ECM) Voltage Supply, Checking With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuses 10 and 29 OK - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Generator OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 Page 6275 - Remove pump. Installing - Fill power steering pump with hydraulic oil, via suction union. - Turn hub by hand until oil comes from pressure side. - Install power steering pump on bracket and tighten bolts to 25 Nm (18 ft. lbs.). - Install suction hose and spring clip. ^ (Arrow A) must align with casting seam -arrow-. ^ Spring clip must close off mark -arrow B-. - Install new O-rings on banjo bolt. - Tighten banjo bolt to 30 Nm (22 ft. lbs.). Continue installation in reverse sequence Page 1496 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 2897 Part 2 Page 2535 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 5837 Part 2 Page 3901 - Vehicles with engine code BDF, item 7. Note the following when installing the fuel injectors: - Replace O-rings on all fuel injectors and wet them slightly with clean motor oil. - Insert fuel injectors into fuel rail perpendicular and in the right position, and secure them with retaining clips. - Position fuel distributor with secured fuel injectors and apply uniform pressure to press it in. - The connectors must audibly engage on valves when attached. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 2425 Part 1 Page 4408 - Connect multi-pin connector to TCM -J217- pins (arrows) and lock connector. Performing On Board Diagnostic (OBD). See: Transmission Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/Scan Tool Testing - 4 Speed Automatic 01M/Scan Tool Connecting and Initial Checks/Connecting VAG 1551 Scan Tool - Initiating basic setting. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Programming Trans Control Module (Basic Setting, Initiating) - 4 Speed Automatic 01M Transmission Control Module (TCM) -J217- 68-pin connector assignment (socket numbers on VAG 1598/18) 1 - Ground (terminal 31) 2 - Vacant 3 - CAN-Bus Low input and output signals 4 - Vacant 5 - Vacant 6 - Transmission Fluid Temperature Sensor -G937 - Vacant 8 - Vacant 9 - Solenoid valve 3 -N90- 10 - Solenoid valve 7 -N9411 - Park/neutral signal 12 - Vacant 13 - Vacant 14 - Vacant 15 - Brake Light Switch -F- signal voltage 16 - kick Down Switch -F817 - Vacant 18 - Multi-Function TR Switch -F125- (pin 5) 19 - Vacant 20 - Vehicle Speed Sensor -G6821 - Transmission Vehicle Speed Sensor -G3822 - Solenoid valve 6 -N93- supply voltage 23 - Supply voltage (terminal 15) 24 - OBD K-wire 25 - CAN-Bus High input and output signals 26 - Vacant 27 - Vacant 28 - Vacant 29 - Shift Lock Solenoid -N11030 - Vacant 31 - Vacant 32 - Vacant 33 - Vacant 34 - Vacant 35 - Vacant 36 - Vacant 37 - Vacant 38 - Vacant 39 - Vacant 40 - Multi-Function TR Switch -F125- (pin 2) Page 5825 Battery: Specifications Current Draw Max. .............................................................................................................................. ........................................................................ 25 mA Page 2943 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Page 5139 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2557 Water Pump: Testing and Inspection Coolant feed pump (V51), checking Special tools, equipment, test and inspection devices; required accessories - VAG 1527 B Voltage tester - VAG 1594 A auxiliary measuring tool set Test conditions - Fuse # 16 OK Test sequence - Disconnect two-way connector from coolant feed pump -V51-. Service and Repair Power Steering Line/Hose: Service and Repair For information regarding this component and the system that it is a part of, please refer to Power Steering Pump. Page 1890 Wheels: Specifications Wheel bolts to wheel hub for all vehicles ............................................................................................................................................ 120 Nm (88 5 ft. lbs.) Page 3911 - Only disconnect or connect with ignition switched off. - Release to disconnect. 5 - Motronic Engine Control Module (ECM) - J220 -. Located in plenum chamber. - Check voltage supply 6 - 10 Nm. 7 - Retaining Frame. 8 - 40-pin Harness Connector. Only disconnect or connect with ignition switched off. - Release to disconnect. 9 - From Brake Booster. 10 - From Evaporative Emissions (EVAP) Canister Purge Regulator Valve - N80 -. EVAP system. Page 3236 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Checking voltage supply terminal 30 - Measure supply voltage between test box sockets 1 + 62 using multimeter and adapter cables from VW1594: Specified value: at least 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from battery (B+) voltage, the readiness code must be generated again. Checking voltage supply terminal 15 - Measure supply voltage between test box sockets 2 + 3 using multimeter and auxiliary cables from VW1594. - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Voltage Supply For Engine Control Module (ECM), Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 134 Door control module, rear left and rear right Door Control Module, Driver Side J386 - Door control module, driver side Door Control Module, Passenger Side J387 - Door control module, passenger side Door Control Module, Rear, Left Page 5725 Service and Repair Shift Cable: Service and Repair 5 Speed Manual 02J Selector cables, removing and installing Note: Lubricate all mountings and sliding surfaces with Polyurea grease Part No. G 052 142 A2. 1. Gear selector cable - Press onto gear shift guide - Installation position 2. Gate selector cable - On gate selector bracket - Installation position 3. Circlip 4. Circlip - Do not damage cable when removing 5. Selector housing 6. Support bracket 7. Bushing - Support bracket mounting to transmission 8. Distance piece 9. Hex bolt, 25 Nm Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 4321 Page 3928 12 - Switch-over valve 13 - Activated charcoal canister In the rear right wheel housing underneath the liner - Fastened to the body 14 - Leak detection pump for fuel system (V144) On the charcoal canister 15 - Air filter for leak detection pump Page 3349 If the specified value is obtained: - Change to display group 36 as follows: - Press -C- button. - Press buttons -0-, -3- and -6- to input display group number 36 (036) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 36 -> 1234 - Depress brake pedal and hold. NOTE: Engine speed will be increased by Engine Control Module (ECM). - Check oxygen sensor voltage in display field 1. - Allow engine to run at an increased speed until specified value "B1-P2 OK" appears in display field 4. If the diagnostic is initiated from the Engine Control Module (ECM), the display in display field 4 changes from "Test OFF" to "Test ON." Page 2366 ^ Locate steering column multi-function switch connector on main harness. Vehicles with Multi-function (MFA) display ^ Replace brown/white wire of original harness at the windshield wiper multi-function switch connector T8c/3 with brown/white wire of fuel pump overlay harness. ^ Tape all reworked areas using velour tape. ^ Reassemble instrument panel using a new replacement instrument cluster. Reinstall all trim. ^ Reinstall washer fluid container. ^ Reinstall battery as necessary. ^ Re-connect battery (GND) cable (NO person can be inside vehicle during this step). ^ Code -J533- "Gateway" and Immobilizer functions where applicable. ^ Code instrument cluster and adapt odometer (see Repair Manual Electrical Equipment OBD Group-01) for appropriate MY vehicle. Warranty Information only. Required Parts and Tools 1. Instrument cluster, coolant bottle and fuel pump/fuel sender. 2. Vehicles with Climatronic may require ambient temperature sensor replacement. (see Parts Dept. for correct Part No.) 3. Repair Kit, Part No: 1JM998001 contains: Tip: Page 1955 T 40001-6 - Puller Claw for VW 2.0 Turbo - Accessory Arm (25mm spread) T 40001-7 - Puller Claw for VW 2.0 Turbo; Accessory Arm Page 3277 Master Diagram Index: To locate the diagrams by component name, please refer to the Master Diagram Index at the vehicle level. See: Diagrams/Electrical Diagrams/Master Diagram Index Driver Heated Seat Control Module Seat Heater Control Module: Locations Driver Heated Seat Control Module J131 - Driver's heated seat control module Page 3058 Display Group 4 Evaluating display group 4, display field 4-Intake air temperature Diagram Information and Instructions Seat Heater Control Module: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 3485 Display Group 060 - Terminate engine basic setting at earliest after 30 seconds by pressing -> button. Adaptation has been performed successfully. To store the values: Page 2533 Continuation of test if indication is approx. -40 degree C: Vehicles with engine code AFP - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Vehicles with engine code BDF - Disconnect 4-pin connector from Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2- (arrow) Continuation for all vehicles - Bridge terminals 3 + 4 of connector using the respective adapter cables and observe the indication on display. If indication jumps to approx. 140 degree C: - End diagnosis and switch ignition off. - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23, -Vehicles with engine code BDF, item 14. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5279 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Climatronic Components - Engine Compartment Outside Temperature Display Sensor: Locations Climatronic Components - Engine Compartment Climatronic Components - Engine Compartment Page 2870 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor Before TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control Before TWC, Checking, With Manufacturer's Scan Tool. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control Before TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. Recall - Check/Replace ABS Control Unit Technical Service Bulletin # WJ-US Date: 020301 Recall - Check/Replace ABS Control Unit WJ-US Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Relay Locations Compiled From Every Wiring Section 1998-2004 Fuel Pump Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor: Locations Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor Location G39 Page 4998 Fluid - M/T: Fluid Type Specifications 02J Manual Transmission Transmission fluid DYP, ECW, EFG, ERS, FBV, FBX, FBY, EGY, EVR, EZK, FCF, G51 ................................................................................. SAE 75w-90 (synthetic oil) DQY, DBZ, DZQ, DZC, EGC, EGF, EKG, EMR, EMS, ENH, ENJ, EBJ, EBP, EBQ, EZH, EWW, FBW, EGR, EBN, EGT, EGX, EGU, EHC, FDS, EHA Type ............................................................... ...................................................................................................................... G50 SAE 75w-90 (synthetic oil) 02M Manual Transmission Transmission fluid Type ....................................................................................................................... .............................................................. G51 SAE 75w-90 (synthetic oil) Page 491 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Connect multimeter to measure voltage at terminals -2- and -6-. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. - Connect multimeter to measure voltage at harness connector terminal -2- and Ground. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. Page 6107 Fuse arrangements in fuse bracket/battery S162 - Fuse -1- (30) In Fuse Bracket/Battery Page 5974 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1190 - Check wires between test box and 4-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 93 Terminal 4 + socket 108 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Measure resistance at Engine Coolant Temperature (ECT) Sensor - G62-, terminals C (signal) and D (Ground -GND-). Range A displays resistance values for the temperature range of 0 to 50 degree C, range B displays resistance values for the temperature range of 50 to 100 degree C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Engine Coolant Temperature (ECT) Sensor -G62- with Engine Coolant Temperature (ECT) Sensor -G2-: Vehicles with engine code AFP, item 23 , - Vehicles with engine code BDF, item 14 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 935 Part 2 Page 5147 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Page 19 Display Group 22 - Key status (not) OK "0" A faulty key or key without transponder has been used - An ignition key with an incorrect type of transponder was used (fixed code transponder) - Induction coil malfunction, check DTC memory. See: Reading and Clearing Diagnostic Trouble Codes/Displaying and Reading Trouble Codes/With Manufacturer Scan Tool - Number of adapted keys: "2" If value in display fields 1 - 3 is 1: Locations Shift Interlock Solenoid: Locations N110 - Shift lock solenoid Page 5844 Battery: Technician Safety Information Warnings and Safety Measures For Lead-Acid Batteries Warnings And Safety Measures For Lead-acid Batteries WARNING! 1 - Keep open flames and sparks away and DO NOT smoke near batteries! Avoid sparks when working with cables and electrical units. - Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing. 2 - Always wear eye protection when working with electrolyte! If electrolyte gets into eyes, flush with large quantities of water. Seek medical attention immediately! 3 - Keep children away from batteries! 4 - Dispose of batteries properly! Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal 5 - Never dispose of batteries in household waste! 6 - Danger of explosion! - Batteries produce explosive gasses while being charged. - Keep open flames and sparks away and DO NOT smoke near batteries. - The battery charger MUST be turned off when connecting or disconnecting the cables at the battery. - Battery cell caps must NOT be removed while charging. - Ensure that battery is charged in a well ventilated area. - Avoid short circuits. Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing. 7 - Read and follow all instructions on battery. 8 - Battery acid can cause severe burns! When working with electrolyte always wear eye protection, rubber gloves and a suitable apron. If electrolyte is spilled on eyes, skin, clothing (or painted surfaces), flush at once with large quantities of water. - Never tip a battery on edge. Electrolyte can spill from the ventilation openings. Batteries With Central Gas Venting Batteries With Central Gas Venting Batteries with two different styles of central gas venting are installed: - Batteries with central gas vent hose - Batteries without central gas vent hose CAUTION! - Only new generation batteries with central gas venting are to be installed! - For proper function of central venting and flame trap, check vent hose (where applicable) for proper installation. Vent hose must NOT be disconnected or pinched. - Only the use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. - Only use genuine VW cell caps of the same construction if lost or damaged. - Caps must be fitted with an O-ring seal. Page 2793 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no sensor malfunction is detected: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3- pin harness connector for open circuit according to wiring diagram. Terminal -1- + socket 108 - Terminal -2- + socket 90 - Terminal -3- + socket 82 - Wire resistance: max. 1.5 ohms - Additionally check wires for short to one another. If no malfunction is found in the wiring: - Remove sensor and check sensor wheel for secure fit, damage and run-out. NOTE: There is a larger gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If no malfunction is detected on sensor wheel: - Replace Engine Control Module (ECM). Locations Power Protection Relay: Locations Relay Panel & Thirteenfold Auxiliary Relay Panel Above panel break 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for motor remote unlock rear lid (79) 3 - Starting Interlock Relay (53)/(465) 4 - Fog Light Relay (53) 5 - Control module for multi-function steering wheel (450) 6 - Control module for multi-function steering wheel (450) 7 - Daytime Running Lights Change-over Relay (173) 9 - Dual Horn Auxiliary Relay (53) 10 - Glow plug relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Below panel break 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18)/(100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (377)/(389)/(192) VI - Wiper/Washer Intermittent Relay (377)/(389)/(192) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 3061 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Mass Air Flow (MAF) sensor -G70-, item 4. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Page 5702 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 1115 Hazard Warning Switch: Service and Repair Emergency Flasher Switch -E3- Removing and Installing Switches In Instrument Panel, Removing And Installing Switches consists of a switch housing and trim plate with relevant symbol. The trim plate is clipped onto the switch housing. If the trim is released instead of the switch during removal, the trim must be re-clipped onto the switch housing afterwards. Remove switches with connected wiring from instrument panel opening prior to disconnecting electrical connection on rear of switch. If necessary, temporarily remove switch to the left of of the switch to be removed/replaced to allow sufficient access to the wiring. NOTE: Switch blank-out covers (where applicable) are removed in the same manner as switches. CAUTION! - Be careful not to damage instrument panel when removing switch. Protect trim in area of switch with adhesive tape before removing switch. - Do Not pry out switches from the side. Only pull out from the top. Rear Window Defogger Switch -E15-, Emergency Flasher Switch -E3- And ASR/ESP Switch, Removing And Installing Page 4928 Special tools, testers and auxiliary items required ^ Torque wrench V.A.G. 1331 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A. G141 0 Note: ^ If a vehicle that has an axle shaft removed is to be moved, an outer CV joint must be installed in place of the axle shaft and be tightened to 50 Nm (37 ft. lbs.) otherwise the wheel bearing will be damaged. ^ Welding and straightening operations are not permitted on load-bearing or wheel-controlling suspension components. ^ Always replace self-locking nuts. ^ Always replaced corroded nuts/bolts Compiled From Every Wiring Section 1998-2004 Starter Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 131 Door Module: Locations Door Control Module, Driver Side J386 - Door control module, driver side Page 5998 Relay Arrangements On The Relay Panel Service and Repair Valve Seat: Service and Repair Valve seats, finishing Necessary special tools, operating equipment, testers, gauges and other aids: Depth gauge - Valve seat finishing tool Procedure Notes: When repairing engines with leaking valves it is not sufficient to just work on or replace valve seats and valves. With longtime engines in particular it is necessary to check valve guides for wear. - Only finish valve seats until a correct contact pattern is achieved. Before finishing valve seats you need to calculate the allowable finishing measurement. If this measurement is exceeded, correct functioning of the hydraulic valve clearance balancing cannot be guaranteed and you must replace the cylinder head. Calculating the maximum allowable finishing measurement - Insert valve and press firmly against valve seat. Note: If the valve is being replaced during repairs, use a new valve for measuring. - Measure distance -a- between valve stem end and upper edge of cylinder head. - Calculate maximum allowable finishing measurement from measured distance and minimum measurement. Minimum measurements: Intake valve: 33.9 mm - Exhaust valve: 34.1 mm Measured distance -a- minus minimum measurement = max. allowable finishing measurement. Example: Measured distance -a- 34.8 mm minimum measurement 34.1 mm = max. allow. finish. measurement 1) 0.7 mm With Manufacturer's Scan Tool Vehicle Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Vehicle Speed Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V - Speedometer OK Test sequence NOTE: To check the speed signal the vehicle must be driven. To do this a second person is necessary. WARNING! Secure scan tool to rear seat and operate from this position. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -5- to input display group number 5 (005) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 5 -> 1234 Page 701 Recall 06V183000: Brake Light Switch Defect Brake Light Switch: All Technical Service Bulletins Recall 06V183000: Brake Light Switch Defect MAKE/MODELS: MODEL/BUILD YEARS: Volkswagen/Jetta 1999-2002 Volkswagen/New Beetle 1998-2002 MANUFACTURER: Volkswagen of America, Inc. NHTSA CAMPAIGN ID NUMBER: 06V183000 MFG'S REPORT DATE: May 24, 2006 COMPONENT: Exterior Lighting: Brake Lights: Switch POTENTIAL NUMBER OF UNITS AFFECTED: 362000 SUMMARY: On certain passenger vehicles equipped with automatic transmissions and cruise controls, a brake light switch on these vehicles may malfunction if it was installed incorrectly during safety recalls 03V-265 OR 04V-096. CONSEQUENCE: The brake lights could become inoperative, or remain on. failure to provide the proper signal when braking could lead to a crash without warning. REMEDY: Dealers will install the newly designed brake light switch free of charge. The recall is expected to begin on or before December 8, 2006. Owners may contact VW at 1-800-822-8987. NOTES: VW recall No. N4. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 2933 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Specifications Crankshaft: Specifications Crankshaft Axial clearance New 0.07 - 0.23 mm Axial clearance Max. wear 0.30 mm Radial clearance New 0.02 - 0.06 mm Radial clearance Max. wear 0.10 mm Main bearing measurements 59.958 - 59.978 mm Connecting rod measurements 53.958 - 53.978 mm Page 3092 - Check wiring between test box and 4-pin harness connector for open circuit according to wiring diagram. Terminal -3- + socket 55 - Terminal -4- + socket 56 Wire resistance: max. 1.5 ohms - Additionally, check wires for short to one another. - Additionally, check wiring for short to battery positive (B+) or Ground (GND). Page 2801 Display Group 4 Continuation of check when display = ambient temperature - Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module. - Note intake air temperature value in display field 4. - Spray sensor (arrow) with commercial chilling agent while observing temperature value. Temperature value must decrease. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation of check when display reads approx. -40.0 °C: Diagrams Fuel Pressure Regulator: Diagrams Evaporative emissions system, diagram Component Overview 1 - Fuel filler door module 2 - Fuel tank 3 - Fuel delivery module 4 - Upper intake manifold 5 - Pressure regulator 6 - Supply rail with injectors 7 - Fuel filter Install position: arrow indicates direction of flow 8 - Solenoid valve 1 for charcoal canister (N80) In the engine compartment on the right Install position: arrow indicates the direction of flow - Check via Output DTM: - Checking operation 9 - Test socket 10 - Gravity/overflow - valve 11 - Pressure retention valve Page 4492 - Pull cover -1- off in direction of arrow. - With ignition switched off, connect tester VAS 5051 to diagnostic connection using cable VAS 5051/3. - Switch tester on. The tester requires approx. 5 minutes to warm up. Switch ignition on. - Select mode of operation: press button on touch screen for "Vehicle self-diagnosis". - Select vehicle system: select "02 - gearbox electronics" on touch screen. - Select diagnostic function: at this point, all diagnostic functions are available. - Select "08 - read measured value blocks" on touch screen. - Press button on touch screen for" basic settings" and continue to display zone for ATF temperature. Test procedures available on the V.A.G. 1551 are described below. Connect V.A.G 1551 Scan Tool and enter address word "02 Transmission electronics" and advance until "Select function XX" is indicated on display. Indicated on display Press keys O and 8 (The function "Read measured value block" is selected with 08). Indicated on display Confirm entry with key Q. Indicated on display Press keys O and 2 (002 selects "Display group number 002"). - Confirm entry with Q key. Indicated on display The third display zone shows the ATF temperature. Note: The ATF temperature must not be more than approx. 30°C at start of test. - Start engine. - Raise vehicle. Service and Repair Clutch Release Fork: Service and Repair 5 Speed Manual 02J Clutch release mechanism, servicing 1. Transmission 2. Ball stud, 25 Nm - Lubricate with MoS2 grease 3. Input shaft oil seal - Replacing 4. Guide sleeve - With vulcanized O-ring - If damaged replace guide sleeve and O-ring together - Lubricate guide sleeve in area of release bearing with MoS2 grease 5. Retaining spring - Secure to clutch release lever 6. Securing bolt, 20 Nm 7. Clutch release lever 8. Release bearing - Do not wash out bearing, only wipe - Replace noisy bearings - Lubricate surfaces which contact release lever with MoS2 grease 9. Securing bolt, 20 Nm 10. Slave cylinder - Removing and installing 11. Plunger - Grease end of plunger with MoS2 grease 12. Assembly bolt - Secures clutch release lever when installing transmission - Unscrew after transmission has been installed Page 2455 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 5732 NOTE: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole - Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket - Remove hydraulic unit with control module from bracket and place on a clean level work bench - Remove the new ABS control module (1C0 907 379 J) from package Insert new adaptor -3- from kit into new ABS control module - Push adaptor down until clips -4- snap into position CAUTION: THE ADAPTER CAN ONLY BE PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 4662 Part 1 Page 817 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. With Manufacturer's Scan Tool Throttle Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Throttle position sensor, checking Special tools, equipment, test and inspection devices; required accessories Special Tools ^ V.A.G 1526 A hand-held multimeter ^ V.A.G 1551 scan tool or V.A.G 1552 system tester with V.A.G 1551/3 cable ^ VAG 1594 A auxiliary measuring tool set ^ V.A.G 1598/31 test box ^ Wiring diagram Function The two throttle position sensors, G79 and G1185, are both on the accelerator and communicate the driver action to the engine control unit independently of each other. The sensors are accommodated in a casing. Test sequence Connect the V.A.G 1551 (V.A.G 1552) scan tool and select the control unit for the engine electronics using "address word" 01. The ignition must be on. Indicated on display: Press the keys "0" and "8" for the function "Read Measuring Value Block" and acknowledge the entry by pressing "Q." Indicated on display: Page 6169 Power Distribution Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 2720 Select function XX NOTE: The next time the ignition is switched "on" the identification of the engine control module is read by the immobilizer control module and stored. Page 3417 If the specified values are not attained: - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector terminals: Terminal 1 + socket 92 - Terminal -2- + socket 83 - Terminal -3- + socket 117 - Terminal -4- + socket 84 - Terminal -5- + socket 118 - Terminal -6- + socket 91 - Wiring resistance: max. 1.5 ohms - Additionally, check wires for short to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive or Ground. Specified value: infinity ohms If no malfunction is found in the wiring: - Check Engine Control Module (ECM) voltage supply. Refer to "Engine Control Module (ECM) Voltage Supply, Checking", See: Engine Control Module/Testing and Inspection Page 3355 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -0- button to confirm input. - Switch ignition off. Continuation Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Power Supply and Cables Check Electronic Throttle Control Module: Testing and Inspection Power Supply and Cables Check Checking the power supply and cables to the control module - Remove driver side shelf: - Disconnect 6 pin connector for throttle position sensor. - Turn on ignition. - To measure voltage, connect multimeter to following contacts of connector: Contact 1 + ground - Contact 1 + 5 - Contact 2 + ground - Contact 2 + 3 - Specification: at least 4.5 V - Turn off ignition. If the specifications are not achieved: - Connect VAG 1598/31 test box to control module wiring. Do not connect engine control module. Page 5873 - Remove M8 x 30 hex bolt -arrow-. - Remove battery hold-down bracket. - If present, disconnect central gas vent hose from top cover. - Carefully lift battery together with insulation from engine compartment. Battery, installing To ensure battery seats securely, only install batteries with a 10.5 mm battery foot strip and adhere to the following work sequences: - Install battery so battery carrier lug - arrow- engages in battery foot strip cut-out -1-. It must not be possible to move a battery to the left or to the right. Page 6306 - Clamp hose on power steering pump with hose clamp 3094. - Remove noise insulation tray. - Place oil pan under vehicle. - Press tie rod end off steering arm. 1 - Ball joint puller (commercial type) e.g. Matra V 176 - Disconnect hoses from steering gear and seal with plastic wrap and adhesive tape. Return line -1can only be removed after lowering sub-frame. - Seal power steering gear threaded holes with plastic plugs. Page 1019 ^ Start engine. ^ Slowly depress brake pedal 15 times. ^ Recheck ECM for DTC. If DTC (P0571) is found: ^ Install new brake light switch. See Installation Procedure below. If no DTC is found: ^ Return the vehicle to customer. Section B - Brake Lights not Operating Correctly If vehicle brake lights do not come on or are constantly on: ^ Using VAS 5051/5052, go to Engine Electronics. ^ Read display value of measuring block 66. Display value should be XX00 with no pedal engagement. ^ Depress brake pedal and display value should change to XX11. If the last 2 digits of either display value are not correct: ^ Install new brake light switch. See Installation Procedure below. ^ If the last 2 digits of both display values are correct: ^ Condition is not brake light switch related. DO NOT continue with this technical bulletin. Verify the wiring, connectors, grounds, etc. leading to the brake lights. See Repair Manual for appropriate wiring diagrams. Installation Procedure ^ Switch ignition to the OFF position and remove ignition key. ^ Remove the lower dash cover fasteners -1-. ^ Pull cover -2- out of rear holding clips and set cover aside. Page 6004 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2711 - The respective fuses of Motronic Engine Control Module (ECM) - J220- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Generator (GEN) must be OK, checking. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. Test sequence - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Checking voltage supply terminal 30 - Measure voltage supply between sockets 1 + 62 and 2 + 62 of test box. Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram: - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking voltage supply terminal 15 - Measure voltage supply between sockets 1 + 3 and 2 + 3 of test box. - Switch ignition on. - Specified value: at least 11.5 V If specified value is not obtained: - Check wire connections to relay carrier and Ground (GND) connection of Engine Control Module (ECM) according to wiring diagram. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 57 - Antenna Selection Control Module -J515- (Diversity box) -3-: ^ Location Wagon; behind left luggage compartment side trim, below rear side window. ^ Location, Sedan: under rear parcel shelf. Antennas: All models use four antennas -1-, -8-. ^ Location Wagon: Integrated with rear side windows. ^ Location Sedan: Integrated with rear window. Antenna amplifiers: All models use four antenna amplifiers -2-. ^ Location,Wagon: 2 each behind left and right luggage compartment side trim, below rear side windows. ^ Location Sedan: 2 under rear parcel shelf and 1 each behind left and right rear D-pillar trim. Touareg Diagrams Leak Detection Pump: Diagrams Evaporative emissions system, diagram Component Overview 1 - Fuel filler door module 2 - Fuel tank 3 - Fuel delivery module 4 - Upper intake manifold 5 - Pressure regulator 6 - Supply rail with injectors 7 - Fuel filter Install position: arrow indicates direction of flow 8 - Solenoid valve 1 for charcoal canister (N80) In the engine compartment on the right Install position: arrow indicates the direction of flow - Check via Output DTM: - Checking operation 9 - Test socket 10 - Gravity/overflow - valve 11 - Pressure retention valve Page 6377 - Clamp steering gear in vice and remove tie rod. Installing Install in reverse sequence. Tightening torque: Tie rod to power steering gear 75 Nm (55 ft. lbs.) Installing boot - Check boot for wear (cuts, cracks) and ensure sealing surfaces are clean. - Install boot, but first turn tie rod so tie rod end is in installed position. NOTE: Only use genuine clamps. Tension clamp with pliers VAG 1275. - Install power steering gear. Page 2140 Oil Pressure Sender: Testing and Inspection refer to Oil pressure and oil pressure switch, checking Special tools, equipment, test and, inspection devices; required accessories Special Tools ^ V.A.G 1342 Oil pressure tester ^ V.A.G 1527 B Diode test lamp ^ V.A.G 1594 A Supplemental measuring tool set Function of the Dynamic Oil Pressure Warning System The oil pressure switch is open without pressure and is closed when the operating pressure is reached. The oil pressure warning is actuated approximately 10 seconds after the ignition is turned on. Oil pressure warning turn-on delay: approximately 3seconds. Oil pressure warning turn-off delay: approximately 5 seconds. Checking the indicator light for operation with oil pressure After the ignition is turned on, the indicator light (K3) in the instrument panel must light for approximately 3 seconds and then extinguish. The test ends when the engine starts running. Warning criteria Warning is provided both visually (blinking indicator light) and acoustically (buzzer sounds three times). This occurs under the following operational states: ^ Ignition ON, engine stopped, oil pressure switch closed ^ Engine speed above 1500/min, oil pressure switch open Notes: ^ The indicator light is not switched off if the engine speed exceeds 5000 rpm, not even if the oil pressure switch is closed. The indicator light will be shut off again when the engine speed drops below 5000 rpm. ^ If the oil pressure switch is only opened for 0.5-3.0 seconds when the engine speed is over 1500 rpm, this fact will be stored in the instrument cluster processor. If this state occurs three times while the engine is running, the warning will be triggered and will not be cleared even under 500 rpm. The warning will be cleared when the oil pressure switch is closed for more than 5 seconds and the ignition is turned off. Test conditions ^ Oil level OK (checking refer to, Fig. 2) Page 629 Test Step 1 Page 5109 Test Step 13 - 14 Test step 15: Multi-Function Transmission Range (TR) Switch -F125- Disconnect connector from multi-function TR switch. Connector pin assignment Page 1456 Part 1 Page 2706 Engine Control Module: Testing and Inspection ECM Voltage Supply Open Circuit, Follow-up Procedure With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply Open Circuit, Correcting All values learned by the Engine Control Module (ECM) and the basic setting values, as well as the readiness code will be erased if the voltage supply is interrupted. Therefore, depending upon the vehicle mileage, it can lead to serious engine running problems. Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test sequence Perform the following operations after voltage supply open circuit: - Switch ignition on for at least 10 seconds. - Switch ignition off. - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. - Check idle speed. Refer to "Fuel Delivery and Air Induction/Idle Speed", See: Fuel Delivery and Air Induction/Idle Speed/Testing and Inspection - Generate readiness code. NOTE: During idling check the Evaporative Emission (EVAP) canister purge regulator valve -N80and the air conditioner are switched off, and the oxygen sensor control learning procedure is initiated. - Perform longer road test until poor driving characteristics are eliminated. Observe the safety precautions when carrying out a road test. During the road test the following operating conditions must be fulfilled: - The coolant temperature must exceed 80 °C When temperature is reached, operating conditions: - Idling - Part throttle - Wide Open Throttle (WOT), and - Overrun must be obtained several times. At Wide Open Throttle (WOT) the speed must exceed 3500 RPM. Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 4403 Test Step 7 - 15 Page 2823 - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 6126 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2239 - Lock vibration damper in position with locking bracket 3406. - Tighten sprockets 3 and 4 for intermediate shaft to 100 Nm. - Remove locking bracket 3406. - Check position of crankshaft in relation to intermediate shaft. The ground tooth of drive gear -Bmust be aligned with the bearing parting line (TDC cyl. 1). Install camshaft roller chain and chain tensioner with tension bar: Set both camshafts to TDC cyl. 1. - Align camshafts with camshaft guide 3268. - Install bearing bolt for tension bar and tighten to 18 Nm. - Install tension bar for chain tensioner (camshaft roller chain). Page 3864 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Page 5037 - Separate front exhaust pipe -A-.Refer to Exhaust Systems. - Remove cross support -B- below exhaust system. - Loosen heat shield -C- in forward area. - Remove heat shield -D-. - Unbolt selector housing from body. - Swing gear lever housing down and remove with selector cables. Installing Installation is carried out in the reverse sequence. Also, note the following: Align gear lever housing parallel to body. Distance to body must be same on both sides. Adjusting selector mechanism. Tightening torques Selector housing to body 25 Nm Cross support to body 25 Nm Selector cable support bracket to transmission 25 Nm Selector cable bolt to transmission selector lever 25 Nm Balance weight to transmission selector lever 25 Nm Disassembling and Assembling 5 Speed Manual 02J Transmission selector mechanism, disassembling and assembling Page 633 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Page 97 If reception does not return: ^ Problem is located further forward in the system. For problems forward of the antenna system: - Continue with Section 3a. For problems at antenna system: Skip to Section 3b. For problems at antenna systems: Tip: All checks should be done outdoors away from buildings. Section 3a - Problems forward of antenna system - First verify connection at Radio (check for bent or crushed connections and proper fit). If all connections appear ok: - Ground antenna lead at radio or attach external antenna mast to radio unit (check for reception). If reception returns: ^ Problem is located between radio and antenna. - Check connections near center console: If connections are OK: - Check resistance of cable from end to end. ^ If More than .4 ohms: - Replace cable. If reception does not return; - Replace radio unit. Section 3b - Problems at antenna system, Diversity Antenna (Touareg, Passat W8) If concern is only AM poor / no reception; Locate AM antenna amplifier. ^ Touareg: located above left side window. ^ Passat W8: Sedan above rear window. ^ Passat Wagon: located on left rear window. - Check for proper connections at amplifier both from diversity box and to glass. If connection issue is at glass or on glass: - Glass must be replaced. If connection problem to amplifier: - Repair connection (replace cable or amplifier). Page 1379 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Powertrain Management/Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Engine Controls - Silicone Sealer/Lubricant Precautions Oxygen Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 1220 Management/Ignition System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 3506 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 3167 - Vehicles with engine code AFP, item 10, - Vehicles with engine code BDF, item 12. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If specified value is obtained: - Check voltage supply of throttle valve control module and wiring to control module. - Check Throttle Position (TP) Sensor -G79- and Sender -2- for accelerator pedal position -G185-. See: Sensors and Switches - Computers and Control Systems/Throttle Position Sensor/Testing and Inspection If voltage supply and wires are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Checking voltage supply and wiring to control module - Connect multimeter to connector terminals 2 + 6 for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. - Connect test box to control module wiring harness connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram: Terminal 1 + socket 92 Terminal 2 + socket 83 Terminal 3 + socket 117 Terminal 4 + socket 84 Terminal 5 + socket 118 Terminal 6 + socket 91 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: Page 3227 Engine Control Module: Application and ID Control Module Identification and Equipment Control Module Identification The control module version is displayed when the VAG1551 Scan Tool (ST), the VAG1552 mobile scan tool or the VAS5051 vehicle diagnostic, testing and information system is connected and "Engine Electronics" address word 01 is selected See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Manufacturer's Scan Tool/Connecting VAG 1551 Scan Tool Technical data Engine code AFP System designation Motronic ME7.1 Exhaust emissions conform to: OBD II On Board Diagnostic (OBD) yes Output Diagnostic Test Mode yes Operating mode of data transfer to VAG1551/1552 Rapid data transfer DTC memory Non-volatile memory 1) Readiness Code Memory Volatile memory 2) Heated Oxygen Sensors (HO2S) 2 sensors Knock control 2 knock sensors Twin-path intake manifold yes Variable valve timing no Charge pressure control no Secondary Air Injection (AIR) system yes 1) Independent of voltage supply. 2) Values are erased when voltage supply is interrupted. Page 1396 Installing - Installation is reverse of removal. - Switch on ignition. - Close doors. CAUTION: Make sure no one is in vehicle. - Connect battery Ground (GND) strap. Page 1286 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 6336 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 275 Volkswagen Canada, Inc. Page 553 Engine Control Module: Testing and Inspection Engine Control Module (ECM) Voltage Supply, Checking With Manufacturer's Scan Tool Engine Control Module (ECM) Voltage Supply, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuses 10 and 29 OK - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Generator OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -4- to input display group number 4 (004) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 4 -> 1234 Locations Transmission Speed Sensor: Locations G38 - Transmission Vehicle Speed Sensor (VSS) Page 5271 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 3787 Indicated on display (1-4 "display fields) - Press brake pedal and hold. Note: The engine control unit will increase the engine speed. - Check specifications in fields 1-4. If the diagnosis was started by the engine control unit, the field 4 will jump from "Test OFF" to "Test ON." Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 5708 Owner Letter Page 6138 Fuse Block: Fuse and Fusible Link Locations Fuse Arrangement in Fuse Panel Fuse colors 30 A - green 25 A - white 20 A - yellow 15 A - blue 10 A - red 7,5 A - brown 5 A - beige 3 A - violet Fuse arrangement in fuse panel, behind instrument cluster, left Fuse Arrangement In Fuse Panel Fuses from S24 to S44 are identified with additional prefix 2, in wiring diagram. Example: Fuse S40 on fuse panel is listed as S240 in wiring diagram. Fuses: 1 - Washer nozzle heaters, glove compartment light, memory seat control module 10A 2 - Turn signal lights 10A 3 - Fog light relay, instrument panel light dimmer switch 5A 4 - License plate light 5A 5 - Comfort system 7.5A 6 - Central locking system 5A 7 - Back-up lights, speedomter vehicle speed sensor 10A 8 - Open 9 - ABS 5A 10 - Engine control module (ECM), gasoline 10A - Engine control module (ECM), diesel 5A 11 - Instrument cluster, shift lock 5A 12 - Data link connector (DLC) power supply 7.5A 13 - Brake lights 10A 14 - Interior lights, central locking system 10A 15 - Instrument cluster, automatic transmission 5A 16 - A/C-clutch, after-run coolant pump 10A 17 - Open 18 - Right headlight, high beam 10A 19 - Left headlight, high beam 10A 20 - Right headlight, low beam 15A 21 - Left headlight, low beam 15A 22 - Parking & sidemarker lights, right 5A Page 442 Power Distribution Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 101 - Antenna cables - Touareg 2004 > 2006 Tip: Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information. Page 2794 Engine Speed Sensor: Testing and Inspection With Generic Scan Tool Check Engine Speed (RPM) Sensor Function The Engine Speed (RPM) Sensor -G28- detects engine speed and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test sequence Vehicles with engine code AFP - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Vehicles with engine code BDF - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Continuation for all vehicles Page 4956 VW/Audi axle nut set. Contains:6500-14, 6500-17, 6500 X-30, and 6500 X-32. - 14mm allen for VW Passat 1996-2001, Audi A4; front and rear axle bolts (AWD) - 17mm allen for 1998-2005 VW Passat, 1999-2004 Audi A6, 2002-2005 Audi A4; front and rear axle bolts (AWD) - 30mm 12 point socket for mid 1999-2005 VW Golf, Jetta, Cabrio, and Beetle; front axle nut - 32mm 12 point socket with a 3/4" drive, VW Touareg; front and rear axle nuts Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: 6500-14 - 14mm Allen Socket Page 1865 The display shows: - On the display, press Go to Button -arrow-. The display shows: - On the display, press the Exit button -arrow-. - On the exit menu, press Exit button. - Turn the ignition off and disconnect the diagnosis connectors. - Turn the ignition on. When the ignition is turned on, no service will be shown on the instrument panel odometer display. - Turn the ignition off. Page 1369 - Insert steel wire (approx. dia. 1.2 mm) in drilling next to ignition key -arrow-. NOTE: - To enable steel wire to be inserted straight into hole, ignition key may have to be dismantled and inserted into lock cylinder without key head. - Dismantle ignition key if necessary. - Release lock cylinder securing lever using wire -arrow- and remove lock cylinder from steering lock housing. 1 - Lock cylinder 2 - Steel wire (approx. dia. 1.2 mm) Page 10 Alarm Module: Component Tests and General Diagnostics Anti-theft Immobilizer, Troubleshooting Requirements - Voltage supply OK. - Diagnostic wire between instrument cluster and VAG-1551 OK. - Valid wiring diagram and Repair Manual available. Malfunction - Engine does not start (when starting, engine runs and stalls after approx. 1 second) - Connect VAG 1551 and initiate On Board Diagnostic (OBD). - Select engine control module with address word 01. - Check DTC memory (function 02). Possible cause - DTC 17978 -"Engine control module blocked" is stored in DTC memory The immobilizer control module electronics have not released the engine control module! - Erase DTC memory (function 05) and end output (function 06). - Select instrument cluster OBD with address word 17. - Check DTC memory (function 02), evaluate and correct malfunctions using DTC table. See: Reading and Clearing Diagnostic Trouble Codes/Displaying and Reading Trouble Codes/With Manufacturer Scan Tool NOTE: After completing the repairs and adapting the immobilizer components it is absolutely necessary that the engine control module DTC memory is checked and erased. - DTC 17978 "Engine control module blocked" is not stored in DTC memory, this means: There is no malfunction of the electronic immobilizer! - Perform troubleshooting according to instructions. Malfunction - Key adaptation faulty - DTC 01179 "Key programming faulty" is stored in DTC memory of immobilizer control module - Select instrument cluster OBD with address word 17. - Press -> button. Indicated on display (example) IMMO-IDENT No.: VWZ7ZOV0066808 -> - Compare 14-digit identification number shown in display with identification number on key fob. - If identification numbers are different, determine secret number corresponding to immobilizer identification number in display. The correct secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14-character immobilizer identification number. - Adapt all keys with correct secret number. Malfunction - "Fail" appears in odometer display in instrument cluster and engine does not start - An incorrect secret number has been entered 3 times Corrective measure - Perform "Login procedure" function 11. Page 6445 Special tools, testers and auxiliary items required ^ Torque wrench V.A.G. 1331 ^ Torque wrench V.A.G. 1332 ^ Torque wrench V.A. G141 0 Note: ^ If a vehicle that has an axle shaft removed is to be moved, an outer CV joint must be installed in place of the axle shaft and be tightened to 50 Nm (37 ft. lbs.) otherwise the wheel bearing will be damaged. ^ Welding and straightening operations are not permitted on load-bearing or wheel-controlling suspension components. ^ Always replace self-locking nuts. ^ Always replaced corroded nuts/bolts Page 3760 Vehicles with engine code AFP - Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Vehicles with engine code BDF - Check wire between 2-pin connector terminal 1 and Ground (GND) for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms Continuation for all vehicles If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1163 - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of the respective connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace the respective hall sensor: Camshaft Position (CMP) Sensor -G40-, item 16 , - Camshaft Position (CMP) Sensor 2 -G163-, item 13 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes Page 3243 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Coding Engine Control Module (ECM), Coding NOTE: - A 5-character code must always be displayed during the control module identification. - The control module must be recorded if the vehicle relevant coding is not displayed or the control module has been replaced. Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -7- to select "Code Control Module" function 07 and press -Q- button to confirm input. Indicated on display Code Control Module Enter code number XXXXX (32000) - Enter relevant code number for vehicle and press -Q- button to confirm input. Coding variants: Coding Vehicle 00031 Manual Transmission 00033 Automatic Transmission The control module identification and coding are indicated on the display, (example) 0219060186 MOTRONIC ME7.1G V06 -> Coding 00000 WSC 00000 Indicated on display when a non-authorized code number has been entered Function is unknown or -> cannot be carried out at the moment. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. NOTE: The code entered and shown on the display will not be used by the Motronic control module until the ignition has been switched off once. An incorrect coding leads to: - Engine running malfunctions (rough gear changes, load change jerks, etc.). - Increased fuel consumption. - Increased exhaust gas emissions. - Malfunctions stored in DTC memory which are not actually present. - Functions will not be performed (Oxygen Sensor (O2S) control, activation of the EVAP system, etc.). - On front wheel drive vehicles the traction control will not function (TC warning lamp comes on). Page 555 If the specified value is not obtained: - Remove wiper arms and plenum chamber cover. Page 4410 Test table Page 5328 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Locations Steering Angle Sensor: Locations G85 - Steering Angle Sensor (vehicles with ESP) Page 3540 - Bridge harness connector terminals -1- + -3- using auxiliary cables from VW1594 and observe display. If display jumps to approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item -23-. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. - If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. -40 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Continuation of check when display approx. 140.0 °C: - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). If display jumps to approx. -40.0 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Engine Controls - Avoiding Unnecessary ECM Replacement Engine Control Module: All Technical Service Bulletins Engine Controls - Avoiding Unnecessary ECM Replacement 01 07 54 July 10, 2007 2011168 Supersedes T.B. Group 01 number 06-01 dated January 19, 2006 due to additional model year and to add DTC 01314. Condition Engine Control Module (ECM), DO NOT Replace for These Diagnostic Trouble Codes (DTCs) Unnecessary ECM replacement. Vehicle Information Technical Background Diagnostic aid. Production Solution No production change required Service Prior to replacing an ECM for any DTC: Page 1103 Special Tools and Equipment Work Sequence Section A - Emergency Li9ht Switch Replacement ^ Switch off all electrical consumers and remove key from ignition switch. ^ Emergency light switch -3- is the center switch in the instrument panel. ^ To remove emergency light switch, the ESP or ASR switch -2- must be removed, and to remove the ESP or ASR switch, the seat heater switch - 1 - must be removed. ^ If an ESP or ASR switch -2- is located next to the emergency light switch, go to Section B; otherwise, continue. Page 333 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1783 Refrigerant: Fluid Type Specifications A/C Refrigerant .................................................................................................................................... ..................................................................... R134a Page 2607 Service Any evidence of heat shield damage described in the Technical Background section of this bulletin will require replacement of the heat shield. See Repair Manual Group 26 Exhaust system, Emission controls in ElsaWeb. Warranty Information only. Required Parts and Tools No Special Parts Required. No Special Tools Required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Specifications Crankshaft Gear/Sprocket: Specifications Camshaft sprockets Mounting bolts 100 Nm Vibration damper Mounting bolt 100 nm + 1/4 turn Page 4822 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). Page 5778 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Rear Axle 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant G 000 650 2 Hex socket head bolt, 8 Nm (70 inch lbs.) 3 Stub axle 4 Splash shield 5 Wheel hub with wheel bearing and speed sensor rotor ^ Replace each time after disassembly ^ Only replace complete 6 Self locking 12 point nut, 175 Nm (129 ft. lbs.) ^ Replace each time after removing 7 Cap ^ Pressing off and driving in 8 Brake disc 9 Screw 10 Hex bolt, 60 Nm (44 ft. lbs.) ^ With dished spring 11 Axle beam Wheel speed sensor on rear axle, removing and installing Removing ^ Raise vehicle. A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 5294 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3222 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Testing and Inspection Alternator Brush: Testing and Inspection Length of carbon brushes when new: 12 mm Wear limit: 5 mm Tolerance of carbon brushes to each other: + 1 mm Page 5714 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 5425 <-- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit ^ Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION! DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE <-- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) ^ Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws Note Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation ^ Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs) Note Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean ^ Remove yellow plastic plugs and red bracket from hydraulic unit ^ Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) ^ Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on atleast2morevehicles.Only one repair kit will be allocated for every 3 vehicles ^ Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) ^ Remove lint-free clothes from under the ABS control module and hydraulic unit Service and Repair Trunk / Liftgate Switch: Service and Repair Removing - Remove driver's side door panel. - Disconnect harness connectors. - Carefully insert screwdriver between housing and switch and carefully disengage switch from retainer. Installing - Insert button in retainer and engage. - Connect harness connector. - Reinstall driver's side door panel. Page 3809 12 - Switch-over valve 13 - Activated charcoal canister In the rear right wheel housing underneath the liner - Fastened to the body 14 - Leak detection pump for fuel system (V144) On the charcoal canister 15 - Air filter for leak detection pump Page 2365 ^ Place this spliced wire to the right of the steering column keeping wire out of the way. ^ Tape violet/red wire (from main harness back to harness). Tip: To eliminate confusion as wires are spliced, cut wire from position (22) of old connector near its base. ^ Locate the brown/white wire from position (7) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness (stop just short of the last splice connector). Tip: Remember, wire splices must be staggered to reduce the wire bundle size of the complete repair. ^ Cut both wires. Tip: To eliminate confusion as wires are spliced, cut wire from position (7) of old connector near its base. ^ Locate and strip brown/white wire from engine overlay harness. ^ Strip wire from position (7) of cluster overlay harness and twist together with brown/white wire from engine overlay harness. ^ Insert these two wires into a red splice, Part No: 111971940A and crimp. ^ Twist together the two brown/white wires from fuel pump/sender overlay harness. ^ Insert these two wires into the open end of the red splice connector and crimp. ^ Place these spliced wires to the right of the steering column keeping wire out of the way. With special connections to overlay harnesses now complete: ^ Locate wire in position (1) of both connectors. ^ With one wire from each cavity between index and middle finger, slide fingers out along wires towards cluster harness breakout from main harness (stop just short of previous splice). Using a light yellow splice connector Part No: 111971941A: ^ Cut, strip and immediately splice wires. ^ Place this spliced wire to the right of the steering column keeping wire out of the way. Continue splicing wires in this fashion until all wires from original harness have been used. Any unused wires must be taped back to the harness. Page 5465 Front wheel speed sensor wiring, removing and installing Required special tools and equipment ^ VAS 1978 wiring repair set Removing ^ Obtain radio code on vehicles with coded radio. ^ Disconnect battery. ^ Remove Mass Air Flow (MAF) sensor connector -1- from air filter duct. ^ Remove bolts -2- at air filter -3- and place filter to left side. ^ On vehicles with Diesel engines, remove relay panel above brake booster. - Release connector from control module (arrow -1-) and pull off (arrow -2-) Compiled From Every Wiring Section 1998-2004 Transmission Position Relay: Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 313 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 1184 If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If display remains at approx. 140 °C: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check wiring according to wiring diagram. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect 4-pin harness connector from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- (arrow). Page 6033 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 2758 Camshaft Position Sensor: Testing and Inspection With Generic Scan Tool Check Camshaft Position (CMP) Sensor Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - Ground (GND) connections between engine and chassis must be OK. Test sequence (Vehicles with engine code AFP) - Disconnect the 3-pin connector from Camshaft Position (CMP) Sensor-G40- (arrow). - Connect multimeter to terminal 1 (B+) and 3 (Ground -GND-) of connector for Camshaft Position (CMP) sensor for voltage measurement. - Switch ignition on. Specified value: at least 4.5 V With Manufacturer's Scan Tool Vehicle Speed Sensor: Testing and Inspection With Manufacturer's Scan Tool Vehicle Speed Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V - Speedometer OK Test sequence NOTE: To check the speed signal the vehicle must be driven. To do this a second person is necessary. WARNING! Secure scan tool to rear seat and operate from this position. - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -5- to input display group number 5 (005) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 5 -> 1234 Page 5041 Fig. 4 Revised selector cover and selector shaft As of transmission build date 04 09 0 bolt -2- is installed in selector cover -1-. Tightening torque 15 Nm In conjunction with this the stop sleeve is fitted with a bridge -3-. Functional check When shifting down from 5th gear to 4th gear the bolt -2guides the selector shaft over bridge -3- into 4th gear gate. Servicing 5 Speed Manual 02J Gear Selector Mechanism, Installation Position A -Gear change cable B -Gate selector cable C -Heat shield Remove before removing gear selector mechanism. Arrow -A- gear selection movement Arrow -B- gate selection movement Central Control Module For Comfort System Connectors Body Control Module: Locations Central Control Module For Comfort System Connectors Central control module for comfort system Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 4053 Ignition Coil: Testing and Inspection With Generic Scan Tool Ignition Coils With Power Output Stages (Vehicles with engine code BDF), checking NOTE: Ignition coils and power output stages are one component and cannot be replaced separately. Special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1527 voltage test lamp - VAG1594 connector test kit - VAG1598/31 test box - Wiring diagram Test requirements - The respective fuses of ignition coils must be OK. - Motronic Engine Control Module (ECM) Power Supply Relay -J271-must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P-or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Engine speed (RPM) sensor must be OK, checking. See: Computers and Control Systems/Engine Speed Sensor/Testing and Inspection - Camshaft Position (CMP) sensors must be OK, checking. See: Camshaft Position Sensor/Testing and Inspection - Ignition switched off. Test sequence - Remove fuse 29 from fuse holder. NOTE: By removing fuse 29, voltage supply to the fuel injectors is interrupted. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection A/C Pressure Switch F129 A/C Pressure Switch, Electrical Checks Note: The presence of F129 is engine dependant. Where F129 is not used, high pressure sensor G65 is used instead. - Always confirm system use of either F129 or G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10.8mm x 1.8mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan V7 (via the coolant fan control module J293 ) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). A/C Pressure Switch, Functional Checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch N25 engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), F129 switches A/C clutch off. - Check cooling fan function. When system pressure increases, F129 causes coolant fan V7 to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condensor is blocked), F129 switches A/C clutch off. Locations Acceleration/Deceleration Sensor: Locations G419 - ESP-Sensor Unit (vehicles with ESP) Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 5430 Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor: Locations Bank 1, Sensor 1 Oxygen Sensor Oxygen Sensor Location G39 Page 1922 Axle Nut: Specifications Rear 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace Page 2558 - Connect contacts on coolant feed pump -V51 - with battery using auxiliary cables from VAG 1594 A. The pump should start. If the pump does not start: - Replace pump -V51-. If the -V51- starts: - Switch ignition off and on. - Connect VAG 1527 B diode test lamp to disconnected attachment plug of coolant feed pump -V51- using auxiliary cables from VAG 1594 A. The LED should illuminate. Note: This test must be conducted within 10 minutes of the time that the ignition was turned off If the LED does not illuminate: Using wiring diagram find and repair open circuit. Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) Switch - above clutch pedal - above clutch vacuum vent valve -F36- Page 391 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 3399 Part 2 Page 693 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1804 Relay Arrangements On The Relay Panel Fuse Arrangements On The Thirteenfold Auxiliary Relay Panel Fuse Arrangements In Fuse Bracket/Battery Page 865 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 6309 Steering Gear: Service and Repair Power Steering Gear, Overview Power steering gear is not serviceable. Determine cause through pressure and leak tests: If malfunctioning replace complete unit. NOTE: ^ Replace self-locking nuts and bolts. Do not weld or straighten steering components. ^ To grease rack only use steering gear grease Part No. AOF 063 000 04. ^ Replace self locking nuts and bolts. ^ Oil type: Hydraulic oil Part No. G 002 000 ^ Oil system capacity: 0. 7 - 0. 9 ltr (23 - 30 oz.). 1. Tie rod end ^ Checking 2. Nut ^ 50 Nm (37 ft. lbs.) 3. Clamp ^ Replace ^ Tightening 4. Boot ^ Must be straight, not twisted after adjusting tie rod ^ Remove steering gear to replace Page 27 VDO instrument clusters: Warning light for anti-theft immobilizer -K117- goes out. The key in the ignition/starter lock is now adapted. - Press -> button. - Switch ignition off and remove key. - Insert next key in ignition/starter lock and switch ignition on again. Warning light for anti-theft immobilizer -K117- lights up for approx. 2 seconds and then goes out. - When warning light for anti-theft immobilizer -K117- goes out, switch ignition off again and remove key. - Repeat this procedure until all keys are adapted. Warning light for anti-theft immobilizer -K117- flashes briefly after the last ignition key is adapted signifying adapting sequence is completed. NOTE: - If the warning light flashes continuously, key adapting procedure is faulty and must be performed again. - The warning light flashes quickly if the 30 seconds are exceeded when adapting all ignition keys. When the ignition is switched off the time is not registered. Adapting of ignition keys is automatically terminated when: - The total number of keys to be adapted is reached. - An already adapted key is used to switch the ignition on again and the ignition remains switched on for longer than 1 second (DTC is stored) - Permissible adapting period of 30 seconds is exceeded (DTC is stored) after switching ignition on using the 2nd key. - Select "Check DTC memory" function 02. If there is no malfunction stored, adapting of keys has been successfully completed. Page 1207 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Check wiring between test box and 5-pin harness connector -1- for open circuit according to wiring diagram. Terminal -1- + socket 26 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Check wiring additionally for short circuit to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: Page 1678 Coolant: Service and Repair Coolant, draining and filling Special tools, equipment, test and inspection devices; required accessories - VAG 1306 Drip tray for VAG 1202A - VAG 1921 Hose clip pliers - Hydrometer Draining - Open coolant recovery bottle cap. - Remove damping pan. - Unscrew drain plug -arrow- from radiator return to drain coolant from radiator. Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 2806 Intake Air Temperature Sensor: Testing and Inspection With Generic Scan Tool Intake Air Temperature (IAT) Sensor, Checking NOTE: The Intake Air Temperature (IAT) Sensor -G42- is a component of the Mass Air Flow (MAF) Sensor -G70- and cannot be replaced individually. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram - Chilling spray (commercially available) Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 15: Intake air temperature". - Check specified value of intake air temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which is below the ambient temperature of sensor, first check sensor wires for contact resistance. Note that while the vehicle is standing still the sensor might warm up due to radiant heat. If specified value is obtained: - Remove intake air hose between Mass Air Flow (MAF) sensor and throttle valve control module: Vehicles with engine code AFP, item 3, - Vehicles with engine code BDF, item 16. - Remember the intake air temperature value. Page 790 ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting wheel speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert wheel speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect wheel speed sensor to speed sensor wiring. Wheel speed sensor on rear axle (drum brakes), removing and installing Removing ^ Raise vehicle. ^ Disconnect wheel speed sensor and speed sensor wiring connector -1-. ^ Remove bolt -2- from stub axle. ^ Pull ABS wheel speed sensor out of stub axle. Installing ^ Before inserting speed sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650. ^ Insert speed sensor into hole in stub axle and tighten bolt to 8 Nm (70 inch lbs.). ^ Connect speed sensor to speed sensor wiring. ABS wheel speed sensor wiring to rear axle, removing and installing Required special tools Page 4958 6500 X-32 - 32mm, 12-Pt. Socket Page 2867 Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. - Check wires between test box and 6-pin connector (to control module) for open circuit according to wiring diagram. Terminal 1 + socket 70 Terminal 2 + socket 71 Terminal 5 + socket 51 Terminal 6 + socket 52 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to B+ and Ground (GND). Specified value: infinite Ohm If no malfunctions are found in wires: - Replace Heated Oxygen Sensor (HO2S) -G39- bank 1 before catalytic converter: Vehicles with engine code AFP, item 7, - Vehicles with engine code BDF, item 11. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 15 - Connect VAG 1551 Scan Tool (ST) with VAG 1551/3B cable to Data Link Connector (DLC). NOTE: - If nothing is indicated on display, check voltage supply for VAG 1551 scan tool according to wiring diagram. - Depending on the program, additional operating information can be printed out by pressing the HELP button of the VAG 1551 scan tool. - Function 00 "Automatic test sequence" can be performed in operating mode 1 "Rapid data transfer". This automatically checks all control modules installed in the vehicle. - The -> button is used for advancing through the program sequence. - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Initiating & Checking Control Module Versions Anti-theft Immobilizer On Board Diagnostic (OBD), Initiating & Checking Control Module Versions If malfunctions occur in the sensors and components being monitored, they will be stored in the Diagnostic Trouble Code (DTC) memory together with an indication of the type of malfunction. A maximum of 4 DTCs can be stored simultaneously. Sporadic malfunctions are automatically cancelled if they are not repeated in next 50 engine starts. OBD must be initiated at the commencement of troubleshooting and the stored information checked with the VAG 1551/1552 Scan Tool or VAS 5051 Vehicle Diagnostic, Testing and Information System. NOTE: The following description and illustrations deal specifically with the VAG 1551 scan tool. VAG 1552 and VAS 5051 procedures are similar. The information displayed is used in conjunction with a DTC table which has information on the possible causes for pin-pointed repair steps. Test requirements: - All fuses OK according to wiring diagram - Voltage supply OK (at least 11.5 V). - Scan Tool VAG 1551 or VAG 1552 connected. NOTE: - Connecting Scan Tool. Refer to "Scan Tool Testing/Scan Tool Connecting and Initial Checks" See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection - The following description applies only to Scan Tool VAG 1551. Mechanical Specifications Engine Oil Pressure: Mechanical Specifications Oil pressure at idle at least 2.0 bar at 2000 rpm at least 2.0 bar not to exceed 7.0 bar Page 4367 Clutch: Service and Repair 3rd and 4th Gear Clutch 4 Speed Automatic 01M 3rd and 4th gear clutch -K3- with turbine shaft, dismantling and assembling Special tools and equipment - VW 401 Thrust plate - VW 402 Thrust plate - VW 407 Press tool - 3292/1 From assembly tool 3292 Note: The clutch should only be disassembled for cleaning or to visually check parts. The clutches -K1 and -K3- are pressed together. Pressing -K1- off K3- Pressing -K1 onto -K3- Page 4337 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Locations Air Injection Pump Relay: Locations Component Location Component View A/C Pressure Switch -F129- High Pressure Sensor / Switch: Testing and Inspection A/C Pressure Switch -F129A/C Pressure Switch -F129-, Checking NOTE: - The presence of -F129- is engine dependant. Where -F129- is not used, high pressure sensor -G65- is used instead. - Always confirm system use of either -F129- or - G65- and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. The pressure switch can be removed without discharging refrigerant system. - Visually check that O-ring 10,8 mm x 1,8 mm is positioned correctly in the groove. Switch part between terminals 1 and 2 switches off the A/C clutch -N25- when the system pressure is too high or when there is not enough refrigerant in the system. - Switch opens when the pressure is below 1.2 bar and closes again above 2.4 bar (switch point). - Switch opens above 32 bar and closes again below 24 bar (switch point). Switch part between terminals 3 and 4 switches coolant fan -V7- (via the coolant fan control module - J293-) to the next higher fan speed when system pressures increase. - Switch closes above 16 bar and opens again below 12.5 bar (switch point). -F129- functional checks To determine proper A/C system performance, perform the following functional checks with the switch installed and connected. - With the engine running, briefly bridge terminal 1 and 2 of connector. If the A/C clutch -N25engages, the refrigerant circuit is empty. - Check refrigerant capacity (fill). If system pressure is too low (refrigerant leakage), -F129switches A/C clutch off. - Check cooling fan function. When system pressure increases, -F129- causes coolant fan - V7- to switch to next higher fan speed. - Check if A/C system switches off. At excessive system pressures (e.g.: caused by high ambient temperatures or if condenser is blocked), -F129- switches A/C clutch off. Page 2234 - Install Throttle Body. - Install intake air box, please refer to: Vehicle/ Powertrain Management/ Fuel and Air Delivery/ Air Cleaner Housing/ Service and Repair/ See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair. - Reconnect Battery. Relay Locations Compiled From Every Wiring Section 1998-2004 Trunk / Liftgate Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. 4 Speed Automatic 01M Shift Interlock Solenoid: Service and Repair 4 Speed Automatic 01M Shift lock solenoid -N110-, removing and installing Removing Obtain radio code on vehicles with coded radio. - Disconnect battery Ground strap. - Push down sleeve -5- on selector lever handle with two screwdrivers. - Pull selector lever handle off upward. - Remove center console and extension. - Remove locking cable from locking lever. - Disconnect cable tie -1- from selector lever housing. Note: Do not damage wiring! - Pry retainer for connector -2- carefully out of selector lever housing with a screwdriver. - Separate connectors -3- for shift lock solenoid and -4- for selector lever position display. - Release selector mechanism cover strip retaining tabs -6- (Qty. 4) by hand and pry off. - Carefully pry off frame at four corners -7 and remove. Note contact spring for selector lever position display! - Remove locking segment (2 bolts). - Place selector lever in position "1". - Remove retaining bracket -8- (2 nuts). - Remove solenoid securing bolts -9- (Qty. 2) - Remove front selector mechanism securing nuts (Qty. 2). - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove selector mechanism rear securing bolts. - Support selector mechanism from below. Note: Do not bend or kink the selector lever cable. Locations Radiator Cooling Fan Motor Relay: Locations The coolant/condenser fan(s) for this vehicle is/are controlled by the following and does not use relays: Coolant Fan Control (FC) Thermal Switch F18. See: Engine - Coolant Temperature Sensor/Switch/Radiator Cooling Fan Temperature Sensor / Switch/Locations - Coolant Fan Control (FC) Control Module J293. See: Radiator Cooling Fan Control Module/Locations - A/C Pressure Switch F129 (via J293), if equipped. See: Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations - High Pressure Sensor G65 (via J293), if equipped. See: Radiator Cooling Fan/A/C Pressure Sensor/Switch - Cooling Fan/Locations Page 366 Control Module HVAC: Testing and Inspection A/C Control Head -E87- Display, Checking All display segments must show. NOTE: All display segments must appear during output DTM, otherwise replace Climatronic control module -J255-. Page 2946 If specified values are not obtained: - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check wires between test box and 6-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 72 Terminal 2 + socket 73 Terminal 3 + socket 36 Terminal 4 + socket 35 Terminal 5 + socket 33 Terminal 6 + socket 34 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: Infinity Ohms If no malfunction is detected in the wiring and if the voltage supply was OK: - Replace accelerator pedal position sensor, item 4. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Clearing Diagnostic Trouble Codes - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 5735 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 4173 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Page 6340 Part 2 Page 1187 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. Page 6488 Wheels: Specifications Wheel bolts to wheel hub for all vehicles ............................................................................................................................................ 120 Nm (88 5 ft. lbs.) Page 3097 Camshaft Position Sensor: Locations Camshaft Position Sensor Location 17 Camshaft Position Sensor G40 Page 1554 Example of PR label In this example the vehicle is equipped with the standard suspension components 1GA -arrow-. The PR. number can also be e.g. G08, G29, G46, G76 etc. If you encounter a vehicle prior to the above VINs where the PR. number is missing, use the table below to obtain the correct PR. number prior to aligning the vehicle. Tip: Vehicle PR numbers can also be found in Elsaweb under the Vehicle Specific Information heading. Warranty Information only. Required Parts and Tools No special tools required. No special parts required, always see ETKA for the latest parts information. Page 1610 Spark Plug: Tools and Equipment Plug Connector Remover - AST Tool # H 1849-6 Plug Connector Remover AST tool# H 1849-6 Used for spark plug boot removal. Applicable to VW VR6 engine and is comparable to VW tool # T10029. - For the R and R of Spark Plug Connectors - Applicable to VW Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5163 Part 2 Page 5190 Page 5611 <-- Remove clamp -3- and disconnect intake air hose from mass air flow sensor <-- If applicable, remove secondary air hose -4- from air filter box -5<-- Remove screws -6- securing air filter box and remove air filter box ^ If applicable, remove and move aside secondary air relay box and harness from supporting clip ^ If applicable, disconnect electrical connector on brake fluid reservoir <-- Release ABS control module electrical connector by pulling latch upward -arrow 1<-- Pull electrical connector off ABS control module -arrow 2^ Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws ^ Lower vehicle ^ Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle ^ Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor ^ Raise vehicle ^ Close left front and left rear caliper bleed screws when brake fluid stops flowing ^ Lower vehicle ^ Do not remove brake pedal depressor from brake pedal at this time Note: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system ^ Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 1111 Hazard Warning Switch: Locations The Emergency Flasher Switch is Integrated with the Flasher Relay. Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor 3 Mounting Bolt - 10Nm (22 ft. lbs.) Page 2920 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) -G68Removing and Installing VSS -G68Special tools, testers and auxiliary items - Obtain radio code on vehicles with coded radio. - Switch ignition off and disconnect battery ground strap. - Remove battery. - Remove air cleaner. - Install support bar 10-222 A with legs 10-222 A/1 (adapter 10-222 N3 for 6-cyl. engine) and support engine/transmission in position. - Remove bracket for power steering pressure hose. Service and Repair Brake Bleeding: Service and Repair Brake system, bleeding Vehicles with ABS and ABS/EDL When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled using the VAG 1551 scan tool in function 04, "basic setting". WARNING! Do not exceed a filling pressure of 1 bar (14.5 psi) when filling with brake fluid using pressure bleeder US1116. The brake system will not be completely bled if excessive pressure is used. Notes: ^ Bleeding the brake system on vehicles with ABS is the same as for vehicles with conventional braking systems with the exception of using function 04 to bleed systems that have been completely empty. ^ Brake fluid absorbs moisture from the air and must therefore be replaced every two years. Use only new, unused and approved brake fluid that complies with MVSS 116 DOT4. Notes: ^ Brake fluid is poisonous. Also due to its corrosive effect brake fluid must not come into contact with paintwork. ^ Brake fluid must always be stored in airtight containers. ^ Do not use silicone-based brake fluid (DOT 5). Even the smallest trace can cause severe corrosion in the brake system. ^ Rinse off brake fluid spillages using plenty of water. Brake system, bleeding using US1116 pressure bleeder Special tools and equipment required ^ US 1116 brake bleeder ^ Connect brake filling and bleeding unit. ^ Open bleeder valves in specified sequence and bleed brake calipers. Bleeding sequence 1 Right rear caliper 2 Left rear caliper 3 Right front caliper 4 Left front caliper Vehicles with ABS or ABS/EDL ^ Test drive vehicle and perform at least one brake application sufficient to engage ABS regulation. Brake system, bleeding without pressure bleeder ^ Build-up brake pressure in brake system by pumping brake pedal. ^ Connect hose from bleeder bottle to brake bleeder valve at each wheel in turn. ^ Open bleeder valve. ^ Hold brake pedal down, close bleed screw. Note: The brake fluid level in the reservoir must not fall below the MIN mark during bleeding. ^ Release brake pedal. ^ Repeat operation until brake fluid flows without air bubbles. Page 276 Page 1854 Relay Box: Service and Repair Protective Relay Housing In Engine Compartment Protective Housing For Relays In Engine Compartment, Removing And Installing Removing - Remove cover - Press locking lug -arrow- forward and take protective housing off upward out of guides. - Press sides of housing of lower part outward and release carrier plate from locking device. Installing Install in reverse order of removal. Page 3621 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation Page 6015 Relay Arrangements On The Relay Panel Locations Power Steering Pressure Switch: Locations F88 - Pressure switch/power steering Page 1902 Special tools, testers and auxiliary items required ^ Hydraulic removal and installing tool for wheel bearing V.A.G. 1459 B ^ Piston cylinder HKZ-15 with hydraulic press piece E0-204-T ^ Removal rods E-0-217+218 ^ Special nut E-8-214 Thrust tube E-5 ^ Thrust tube E-10 ^ Press sleeve E-13-1 ^ Thrust bolt E-15 ^ Supplementary set V.A.G. 1459 B/2 ^ Bell E-40 - Lift vehicle until the load on the front axle is relieved. - Loosen 12-point nut. - Lift vehicle to installing height. - Remove wheel. The following three work steps are necessary only for vehicles with modified stabilizer bar mounting. - Loosen upper hex nuts of connecting links from left and right suspension strut. - Pull out clamp on brake hose bracket and release brake hose. - Release speed sensor wiring from front suspension strut. Page 2842 - The O2S sensor has been damaged by leaded fuel Checking basic voltage for oxygen sensor 2 - Remove protective cover (arrows) and disconnect 4-pin harness connector (brown) -1 - to oxygen sensor after Three Way Catalytic Converter (TWC) -G130-. - Connect multimeter using auxiliary cables from VW1594 to measure voltage at terminals 3 + 4 (harness connector to Motronic Engine Control Module (ECM)). - Start engine and measure basic voltage. Specified value: 0.400-0.500 V - Switch ignition off. If the specified value is not obtained: - Check oxygen sensor wiring. If the specified value is obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking oxygen sensor wiring, oxygen sensor 2 - Remove wiper arms and plenum chamber cover. Page 1064 - Slowly release brake pedal to stop. Note: The above action automatically adjusts the switch plunger travel. - Reconnect electrical connector to switch. - Check function of brake light switch. "New style" brake light switch, removing and installing Note: The following applies only to a "new style" switch that is removed and replaced. Removing - Turn switch counter-clockwise 45° - Pull switch out from retainer mounting hole. - Dispose of switch accordingly. CAUTION: "New style" switches must NOT be reused after removal. Always replace. Installing CAUTION: "New style" switches have an internal switch mechanism that will be damaged if not installed and adjusted according to the following procedure. DO NOT depress switch plunger or otherwise rotate the retaining collar of the switch prior to installation. Brake pedal must be held in the up position (not depressed during switch installation. - Before installing, pull out plunger -arrow- completely. - Hold brake pedal in up position (against stop). - Note orientation of retainer tabs -1- and -2- on switch and carefully insert switch into retainer mounting hole. - Push switch in and seat fully into opening (pressing plunger against brake pedal to adjust). Page 1149 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 5306 Transmission Temperature Sensor/Switch: Service and Repair 4 Speed Automatic 01M Conductor Strip with integrated Transmission Fluid Temperature Sensor - G93- Removing and installing conductor strip Special tools - 3373 Lever The conductor strip can be replaced with the transmission installed and without removing the valve body. NOTE: Do not kink or damage the conductor strip. Removing and installing conductor strip - Separate connector at transmission and remove retaining clamp. - Drain ATF. - Remove transmission oil pan and remove wiring guide Page 1072 10 - Vacant 11 - Turn signal - terminal R 12 - Switch for dimmer/flasher - terminal 56a Switch for cruise control system D - Harness connector, 10 pin 1 - Vacant 2 - Switch for CCS - On / Off 3 - Buttons for GRA - Set / Delay 4 - Switch for CCS - Reset / Resume saved speed / Accelerate 5 - Switch for CCS - Reset / Resume saved speed / Accelerate 6 - Switch for CCS - On / Off 7 - Switch for CCS 8 - Vacant 9 - Vacant 10 - Vacant Page 3353 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and 4-pin harness connector to Motronic Engine Control Module (ECM) according to wiring diagram. Terminal -3- + socket 68 - Terminal -4- + socket 69 Wire resistance: max. 1.5 ohms - Check wiring at harness connector terminals -3- + -4- for short circuit to terminals -1- + -2according to wiring diagram. Specified value: infinity ohms If no wiring fault is detected: - If no malfunction is found in the wiring, replace Engine Control Module (ECM). Heater Check Heated Oxygen Sensor (HO2S) After Three Way Catalytic Converter (TWC), Checking Special tools and equipment - VAG1551 Scan Tool (ST) Or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements Page 3542 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 708 4 - Coupling station - Installation position: B-pillar - Remove B-pillar lower trim to remove 5 - Door control module, RR For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 6 - Door lock, RR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 7 - Motor for fuel tank lid unlock -V155- remote release Installation position: Under C-pillar trim - To remove, remove trim up to wheel house - Remove with special socket insert T 10010 8 - Rear lid lock Bolted to rear lid - Removing: Remove trim from rear lid. - Remove lock. 9 - Rear lid actuator Bolted to rear lid - Remove with special socket insert T 10010 10 - Door lock, RL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 11 - Coupling station Installation position: rear roof area, covered by roof trim - Remove roof trim to remove. 12 - Anti-theft alarm horn Installation position: In area of C-pillar covered by trim 13 - Door control module, RL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 14 - Coupling station Installation position: B-pillar - Remove B-pillar lower trim to remove 15 - Door lock, FL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 16 - Controls Installed in door trim - Remove door trim to remove 17 - Door control module, FL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 18 - Antenna - for radio frequency remote control - Under left A-pillar trim - Remove A-pillar trim to remove. 19 - Coupling station Page 3426 With battery fully charged: ^ Clear any stored DTC. ^ Perform throttle adaptation procedure (see Repair Group 24, ECM to throttle valve control module, adaptation. ^ Test drive vehicle for approximately one half hour. If MIL does not illuminate and DTC does not return: Low battery voltage has most likely caused the DTC to be stored. ^ Procedure is complete. If MIL illuminates and DTC is stored again, perform the following: ^ Replace ECM (see appropriate Repair Group). Warranty Required Parts and Tools No special tools required No special parts required Page 618 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 4872 Clutch Pedal Assembly: Service and Repair Removing and Installing 5 Speed Manual 02J Clutch Pedal, Removing And Installing Special Tools - 3309 Release tool - 10-208 A Pliers Removing Remove over-center spring. - Separate clutch pedal from master cylinder and push operating rod toward engine compartment onto stop. - Remove nut -A-. - Pull bolt out and remove clutch pedal. Installing Installation is carried out in the reverse sequence, when doing this note the following: Install over-center spring. Page 3181 Spark Plug Pliers - AST Tool # H 1849 Spark Plug: Tools and Equipment Spark Plug Pliers - AST Tool # H 1849 Spark Plug Pliers AST tool# H 1849 Used for the R and R of spark plug connectors and specifically for those with anti-heat terminals. These Pliers are applicable to Mercedes models 190 E and 300 E, and VW/Audi. - Spark Plug Pliers - Applicable to Mercedes, VW and Audi - Steel Construction and Easy-Grip Handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3932 - Open VAG1318 pressure gauge shutoff tap (handle perpendicular to direction of flow). - Start engine and run at idle. - Switch ignition off after pressure has built-up. At same time pinch/seal return line together. If the pressure does not drop: - Replace fuel pressure regulator, item -15-. Refer to "Intake Manifold Lower Section, Disassembling and Assembling", If the pressure drops again: - Check pipe connections, O-rings on fuel rail and fuel injectors for leaks. - Check pressure gauge for leaks. NOTE: Before removing the pressure gauge, place a cloth around the connections to be loosened. Page 3403 Body Control Module: Connector Views Central Control Module For Comfort System; Power Sunroof Control Module Control Modules - Connector Pin-out Page 5207 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Page 434 Page 5613 <-- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Note: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole <-- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket ^ Remove hydraulic unit with control module from bracket and place on a clean level work bench ^ Remove the new ABS control module (1C0 907 379 J) from package <-- Insert new adaptor -3- from kit into new ABS control module <-- Push adaptor down until clips -4- snap into position CAUTION! THE ADAPTER CAN ONLY BE PRESSED BE REMOVED AGAIN WITHOUT PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 5609 Special Tools: Section A Section A - Check ABS Control Module Part Number ^ Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column ^ Switch ignition to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics." ^ Read control module part number and code located in the upper right corner of the screen ^ If ABS control unit part number is 1C0 907 379 C, press <-- button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B ^ If ABS control unit part number is not 1C0 907 379 C no further work is required, press <-- button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code ^ Drive vehicle into hoist area ^ Raise vehicle on hoist Page 5563 8 Piston with - automatic adjustment ^ Apply thin coat of assembly lubricant G 052 150A2 to piston before inserting 9 Sealing ring ^ Removing and installing 10 Brake caliper housing with parking brake cable lever ^ If a leak exists at the parking brake cable lever replace brake caliper housing ^ After repairing, pre-bleed caliper housing Rear brake caliper piston, removing and installing Special tools and equipment required ^ 3272 Piston resetting and removal tool ^ 3409 Wedge ^ Bleeder bottle Removing ^ Remove piston from brake caliper housing by turning knurled wheel counterclockwise. Notes: ^ Install special tool 3272 with the collar (arrow) positioned before the piston. ^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow-A-) provided for this purpose. Page 747 Sunroof / Moonroof Switch: Service and Repair Sunroof Preselector Switch, Removing (Rockwell) Sunroof Preselector Switch, Removing - Unclip trim -1- in direction of arrow and remove. - Remove screws (arrows) and remove preselector switch. - Unclip and disconnect wiring connector. Comfort System and Central Locking System, Assembly Overview Hood Sensor/Switch (For Alarm): Locations Comfort System and Central Locking System, Assembly Overview Comfort System and Central Locking System, Assembly Overview 1 - Coupling station Installation position: Lower A-pillar, covered by trim in footwell - Remove A-pillar lower trim to remove 2 - Door control module, FR For comfort system only - Integrated into window motor - Removing: Remove door trim - Remove window motor. 3 - Door lock, FR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. Page 5273 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Electrical / Mechanical Repair Piston: Electrical / Mechanical Repair Page 675 Page 1266 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 6- pin harness connector for open circuit according to wiring diagram. Terminal -4- + socket 5: Wire resistance: max. 1.5 ohms If the specified value is obtained: - Check wire between 6-pin harness connector terminal -3- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms Aging Check Oxygen Sensor 1 Aging, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1788/10 engine speed adjuster Test conditions - Coolant temperature at least 85 °C display group 04, display field 3 Functional check - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). Indicated on display Rapid data transfer HELP Select function XX Page 4747 Torque Converter: Specifications 5 Speed Automatic 09A 5 Speed Automatic 09A Torque Converter to Drive Plate Bolts 60 Nm Page 5515 Brake Pad: Specifications Brake Pad Thickness Front (FS III Calipers) 14 mm (0.55 in) Front (FN 3 Calipers) 14 mm (0.55 in) Rear 12 mm (0.47 in) Page 4050 - Remove fuse No.32 from fuse holder. NOTE: Removing fuse 32 interrupts the voltage supply to the fuel injectors. - Connect VAG1527B voltage tester with adapter cables from VW1594 to Terminals -5- + -2- (ignition output 1), and - Terminals -5- + -3- (ignition output 3), and - Terminals -5- + -4- (ignition output 2) of disconnected harness connector. - Operate starter and check ignition signal from Engine Control Module (ECM). LED must flicker. - Switch ignition off. If the LED flickers and the supply voltage is OK: - Replace ignition coil -N152-. Refer to item 7, See: Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the LED does not flicker: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. Page 279 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5162 Part 1 Page 5612 <-- Remove brake lines -3- on the side of hydraulic unit CAUTION! DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC CAUTION! MAKE SURE NO BRAKE FLUID <-- From the repair kit provided (1J0 998 375) place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates Note: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION! DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT Diagram Information and Instructions Battery: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 1106 Page 4494 - Pry off plug securing cap -arrow- with a screwdriver. Cap locking device will be destroyed. Always replace cap. - Pull plug out of filler pipe. - Fill with ATF using V.A.G 1924 until ATF runs out of inspection hole. If ATF needs to be topped up, then only ATF with Part No. G 052 990 A2 may be used. Note: An insufficient ATF filling as well as filling to excess affects the function of the transmission. - Fit plug on filler pipe and secure with a new cap -arrow-. - Lock cap. Engine Controls - MIL ON/DTC P1603 (18011) Stored Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P1603 (18011) Stored Group: 01 Number: 05-02 Date: Jan. 14, 2005 Subject: Diagnostic Trouble Code (DTC) P1603 (18011) Stored in DTC Memory Model(s): All with Electronic Power 1999 --> 2005 Control (see table) Condition DTC P1603 (18011) "Control unit faulty" stored in DTC memory. Service DO NOT automatically replace ECM for this condition. First perform the following: - Verify that battery voltage and condition are OK. (Charge and load test as necessary). If battery voltage is low: - Correct reason for low battery voltage. Page 1458 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3316 System/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If the specification is obtained: - Check wiring. Checking wiring - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 3-pin harness connector for open circuit using wiring diagram. -G61-: -G66-: Terminal -1- + socket 106 107 Terminal -2- + socket 99 99 Terminal -3- + socket 108 108 Wire resistance: max. 1.5 ohms - Also, check wires for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Loosen knock sensor and re-tighten to 20 Nm (15 ft lb). - Perform road test again and check knock control specifications on display. Page 1063 Brake Light Switch: Adjustments Brake light switch, removing and installing/adjusting Two different styles of brake light switch were used in production. For servicing purposes they will be referred to here as "old style" and "new style". It is important to identify which style of switch is installed prior to servicing as each requires specific removal and installation/replacement procedures. Notes: On Diesel models and gasoline models with cruise control, Brake Switch -F- and Brake Pedal Switch (cruise control DFI) -F47- are integrated. The following procedures apply to all models regardless of switch. Only "old style" switches can be removed and reinstalled/adjusted. "New style" switches must NOT be reused after removal. Always replace. CAUTION: Should a brake light switch require replacement, only a specific "new style" switch is available (supercedes all previous part number versions). This switch requires that critical procedures be followed prior to and during installation. Preparation - Remove driver's side lower instrument panel cover. - Disconnect electrical connector from brake light switch. - Identify style of switch installed: "Old style" switch is identified by large (approximately 10 mm) plunger tip button, and square plunger shaft. Removing and installing/adjusting below. "New style" switch is identified by small (approximately 4 mm) plunger tip without button, and round plunger shaft. "Old style" brake light switch, removing and installing/adjusting Note: The following applies only to an existing, functional "old style" switch that is removed and reinstalled/adjusted. Removing - Turn switch counter-clockwise 90° - Pull switch out from retainer mounting hole. Installing/adjusting - Before installing, pull out plunger completely. - Depress and hold brake pedal in down position. - Note orientation of retainer tabs on switch and carefully insert switch into retainer mounting hole - Secure switch by turning clockwise 90° Locations Control Module HVAC: Locations J126 - Control module for fresh air blower Page 4910 - Press CV joint on to stop. - Insert circlip. NOTE: Chamfer on ball hub inner diameter (splines)faces contact shoulder on axle shaft. Fig. 6 CV joint boot (left axle), installation position Dimension -a- = 17 mm (0.67 in.) NOTE: Before installing boot mark position, dimension -a-, (for example: paint or adhesive tape). Do not damage paint surface. Fig. 7 Boot for CV joint (right axle), installation position Vent chamber -A- must seat on tube. B - Vent hole Fig. 8 Clamp for CV joint boot (outer), tightening Install VAG 1682 CV joint boot clamp tool, as shown in illustration. Ensure jaws of pliers seat in corners (arrow B) of clamp. - Tighten clamp by turning spindle with torque wrench (do not twist pliers). NOTE: Due to hard material, it is only possible to tighten clamp with VAG 1682 pliers. Tightening torque: 20 Nm (15 ft. lbs.). Use torque wrench -C- with 5 - 50 Nm (5 - 40 ft. lbs.) range (e.g. VAG 1331). - Ensure spindle -A- is not tight. If necessary lubricate with MOS 2 grease. If it's tight e.g. dirty, required torque for clamp will not be achieved in spite of correct torque settings. Page 5868 - Dip end of hydrometer into cell and extract sufficient electrolyte to allow indicator float to swim freely (the greater the electrolyte density in kg/cubic dm, the higher the indicator float position). Note each cell's specific gravity reading from float -arrow-. Repeat sequence until all cells are checked. - Review noted values and compare with values in table below: Charge condition Specific gravity (normal climate) in kg/cubic dm Discharged 1.15 Half charged 1.22 Fully charged 1.28 Example 2: 1.26 1.26 1.25 1.14 1.18 1.24 Example 1: Specific gravity in cell 4 (1.10) is too low. Example 2: Specific gravity in cells 4 (1.10) and 5 (1.18) are too low and variation between cells exceeds 0.04 kg/cubic dm. If specific gravity specifications are not met, replace battery. If specific gravity specifications are met, reinstall cell caps. CAUTION! Only the use of genuine VW battery cell caps ensures the different battery cover systems are sealed correctly. Only use genuine cell caps of the same construction if lost or damaged. All cell caps must be equipped with an O-ring seal. Visual Check Carry out a visual check of the battery before performing measurements such as no load voltage, electrolyte specific gravities or battery load test. NOTES: Performing this test establishes: Whether the battery housing is damaged. Electrolyte can leak out if the housing is damaged. - Whether the battery terminals (battery wire connections) are damaged. Wiring connector contact cannot be guaranteed if the battery terminal is damaged. This may cause a cable to spark or burn, which may cause malfunctions in the electrical system. Page 4064 During the road test the following conditions must be fulfilled: - Coolant temperature must exceed 85 °C. - When temperature is reached, operating conditions Idling, Part throttle, Wide Open Throttle (WOT), and Overrun must be attained several times - At Wide Open Throttle (WOT) engine speed must exceed 3500 RPM - Again, check DTC memory of control module. If the malfunction is still present: - Replace knock sensor/s -G61- or -G66- Refer to item 15 or item 11 under "Ignition System", See: Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased, or Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, readiness code must be generated again. Page 1055 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 6337 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 789 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor on Rear Axle 1 ABS wheel speed sensor ^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant G 000 650 2 Hex socket head bolt, 8 Nm (70 inch lbs.) 3 Stub axle 4 Splash shield 5 Wheel hub with wheel bearing and speed sensor rotor ^ Replace each time after disassembly ^ Only replace complete 6 Self locking 12 point nut, 175 Nm (129 ft. lbs.) ^ Replace each time after removing 7 Cap ^ Pressing off and driving in 8 Brake disc 9 Screw 10 Hex bolt, 60 Nm (44 ft. lbs.) ^ With dished spring 11 Axle beam Wheel speed sensor on rear axle, removing and installing Removing ^ Raise vehicle. Page 3755 - The main fuses must be OK - The battery voltage must be at least 11.5 V. Test sequence - Remove engine cover. - Remove discharge hose on air pump motor. Note: Press the buttons on the hose couplings together. - Remove windshield wiper arms and cowl. - Connect VAG 1598/31 test box to control unit wiring. - Switch ignition on. - Bypass jacks 3 + 46 on test box using auxiliary cables from VAG 1594. The air pump motor should run and air should be coming out the exhaust nozzles. If the motor is running, but no air is coming out: Switch ignition off. - Replace air pump motor V101. If the motor does not start: Page 5323 Volkswagen Canada, Inc. Page 3873 Required Parts and Tools No special tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 4212 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 5977 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2467 5 - Self tapping screw 6 - Fresh air blower -V27 - Cover 8 - Self tapping screw 9 - Series resistor -N2410 - Sheet metal screw 11 - Central flap lever 12 - Temperature flap lever 13 - Base plate 14 - Heater core/bulkhead seal Page 1764 Sh-SW Page 4985 - The engine/transmission angle has changed and therefore the lower edge of the oil fill hole -1- is located below the new oil level -2-. - To properly check oil level, transmission must be drained completely and re-filled. Tip: The transmission housing must be cleaned and dried before servicing. Shift fork pins must be removed in order to drain transmission. Selector shaft, securing ^ Remove air cleaner housing. ^ Remove sound insulation. ^ Clean and dry transmission. ^ Secure selector shaft so that the position of shift fork pins can not move: ^ Press selector shaft down arrow -1^ While selector shaft is held in down position, turn bracket -A- upward (clockwise) in direction of arrow -2- and press inward until the bracket latches in selector shaft. Tip: Use a clean 3.0L container with graduated markings to catch draining oil Transmission, draining Page 2432 Radiator Cooling Fan Motor: Service and Repair For further information regarding this component please refer to Cooling Systems; Service and Repair. Page 699 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3773 If after repairing other fault codes and setting readiness code, and any fault codes in the table return: Replace catalyst(s) as necessary, using applicable SRTs. If software updates do not apply, and only one or more of the following fault codes (DTCs) are present (see table): If DTC text indicates bank 2, bank 3, bank 4: Verify catalyst location before replacement, see Service Manual repair group 26. Use applicable SRTs. For technical assistance, select the "Technical Assistance" tab in ElsaWeb and follow the instructions to obtain a 6 digit pin. Tip: Before repairing vehicle or erasing fault codes (DTCs) remember to make print-outs including freeze-frame data as required and attach to the repair order. If catalytic converter is on parts submission, attach copies of all supporting documentation (including printouts) required when sending parts to Warranty Test Center. Page 6201 malfunctioning electrical consumers, corrosion due to water ingress etc. - All shielded wiring (eg.: knock sensors, antenna etc.) are Not to be repaired! Replace complete wiring harnesses as necessary. - When repairing airbag wiring harnesses, use only prescribed terminals, connectors and wiring. - Only the yellow repair cables and insulation tape supplied with VAS 1978 are to be used for wiring/connector repairs. The use of yellow repair wires and yellow insulation tape identifies that a repair has taken place! - When repairs are completed, always perform a functional check of the component or system. Where applicable, check and erase Diagnostic Trouble Codes (DTCs) and set basic setting. - Additional information on removal and installation of electrical and related components. 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 3053 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 43 - Antenna cables - double DIN (Premium VI) radio. - Antenna cables - Phaeton 2004 > 2006 - Antenna cables - Satellite radio (Hard top vehicles) Page 332 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 6259 10. Ribbed belt CAUTION: ^ Using a crayon or marker, mark the direction of travel before removing the ribbed belt. Reinstalling a used belt in the opposite direction could damage the belt. ^ When installing the belt make sure that it is correctly seated in the pulleys. ^ Determine part number from parts catalog ^ Check condition 11. Ribbed belt tensioner Page 4404 Test Step 16 - 17 After electrical checks: - Fit multi-pin connector onto control module - J217- pins -1- then lock multi-pin connector -2-. NOTE: When fitting connector ensure that the guides are engaged on the control module pins. Page 2024 Piston: Aftermarket Tools VR-6 Piston Installation Tool AST tool# 3278 Used for piston installation on all VW models with VR-6 engines. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 5536 Warranty Interior - Rattles Near Center Air Outlet Air Register: Customer Interest Interior - Rattles Near Center Air Outlet Group: 80 Number: 04-01 Date: Aug. 5, 2004 Subject: Dash Panel, Rattles Near Center Air Outlet Model(s): Jetta 1999 --> 2004 see VIN Below Condition Rattles near center air outlet of dash panel, when driving over rough roads. Production As of VIN: 3VWRA69M74M133075, two felt strips (12 mm X 15 mm X 1 mm) have been installed where the center air outlet slides into the air duct. Service For vehicles prior to 3VWRA69M74M133075: - Remove center air outlet (see Repair Manual Repair Group 80 - Heating, Ventilation Air outlets, removing Center air outlet (Jetta), removing). With air outlet removed: - Cut two pieces of adhesive backed felt (12 mm X 15 mm) using Part No: 191 861 390D. Note: Part Number can be used for approx. 2.5 vehicles. CAUTION! Part numbers listed in this Technical Bulletin are for reference only. Always check with your Parts Dept. for the latest parts information. Page 5852 Fuse Arrangements In Fuse Bracket/Battery Page 13 - The -> button is used for advancing through the program sequence. - The PRINT button is used for switching on the printer (lamp in button lights up). Indicated on display (* is displayed alternately): VAG - On Board Diagnostic HELP 1 - Rapid data transfer* 2 - Blink code output* - Press button 1 for "Rapid data transfer". - Continue On Board Diagnostic (OBD) of vehicle system to be tested as described under "performing On Board Diagnostic (OBD). Connecting VAG 1551 Special tools and equipment - VAG 1551 Scan Tool (ST) - VAG 1551/3B cable - VAS 5051 Vehicle Diagnostic Testing and Information System VAS 5051 Or VAG 1551, Connecting A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 5347 - Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) - If applicable reconnect air hose -4- from secondary air pump to air filter box -5- Reconnect vacuum line -7- to air box (TDI vehicles only) - Reconnect air intake hose to mass air flow sensor and secure with clamp -3- Reconnect electrical connector -1- to mass air flow sensor -2- Reconnect the ground cable (GDN) from the negative (-) battery terminal - In the vehicle, remove brake pedal depressor from the brake pedal - Proceed to Section D Section D Section D - Code ABS Control Module - Connect VAS 5051 to data link connector located under dash left of steering column - Turn ignition switch to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics" - Select "07 - Code control unit" - Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J - Press the "Q" button to confirm NOTE: On the display, in the upper right corner, the control module part number and coding are displayed - Press (<) button - Select "06 - End output" - Disconnect VAS 5051 from vehicle - Recode radio and reset radio preset stations - Reset clock - Where applicable, reset power window pinch protection - Turn ignition to "OFF" position - Proceed to Section E Section E Section E - Brake Bleeding - Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING: Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 NOTE: Use only Volkswagen approved brake fluid Page 2103 Pe-Ca Page 5276 Part 1 Engine Controls - MIL ON/DTC P0420 Stored in Memory PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0420 Stored in Memory Condition Update Programming, MIL ON, DTC P0420 Stored in ECM MIL ON with DTC P0420 Catalyst System, Bank1 Efficiency Below Threshold stored in ECM. 01 07 06 Jan. 22, 2007 2013839 Supersedes T.B. Group 01 number 06-25 dated Dec. 22, 2006 due to warranty table claim type information change. Technical Background The monitoring strategy for the catalytic converter is too sensitive causing unnecessary catalytic converter replacements. The updated programming of the ECM software makes the monitoring strategy more accurate. NOTE: DO NOT replace catalytic converter due to P0420 if older software level is installed. Production Solution No production change required. Service PROCEDURE: Engine Control Module Update - Programming (Flashing) Tip: When performing the update programming procedure, ALL DTCs for all systems are erased. DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update programming procedure first. The following "Update - Programming" (flashing) process may overwrite any "TUNED" ECM programming. A "TUNED" ECM is described as any ECM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc. If you encounter a vehicle with a "Tuned" ECM, prior to performing the "Update - Programming" (flashing) procedure: Your Dealership should place the vehicle owner on notice in writing, that their ECM was found to have been tuned, and that any damage caused by the tuning of the ECM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties. For any repair requested by the owner under warranty or outside warranty that requires update programming, which will automatically wipe out the "Tuning" program, your Dealership should advise the owner of the above and get Owner's written consent (see attached Control Module Tuning form) to the update programming procedure. Tool requirements VAS 5051 or VAS 5052 (with Base CD V.10.01 and the Brand CD V.10.70.00 or higher). "Update - Programming" (flashing) CD MY99022VVR6CAT. Tip: Additional copies of the "Update - Programming" CD (Literature Number MY99022VVR6CAT) may be ordered from the Volkswagen Technical Literature Ordering Center. Vehicle requirements Battery MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update process can lead to ECM failure) (use an approved battery charger INC940 to maintain battery voltage). VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure. VAS 5052: connected to vehicle with battery voltage requirements met. Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF. CAN-Bus, Checking Engine Control Module: Testing and Inspection CAN-Bus, Checking With Manufacturer's Scan Tool Vehicles with automatic gearbox Function The Engine Control Module (ECM) communicates with the transmission control module via a CAN data bus. The CAN-Bus capable control modules are connected via two data bus wires (CAN_High and CAN_Low) which are twisted together (twisted pair) and exchange information (messages). Information missing on the data bus will be recognized as a malfunction by the Engine Control Module (ECM) and the transmission control module. The CAN-Bus requires a matching resistor of 66 ohms to function correctly. This matching resistor is located in the Engine Control Module (ECM). Special tools and equipment - VAG1598/18 test box - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirement - A malfunction has been recognized by the CAN-Bus On Board Diagnostic (OBD). Test sequence - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check centralized matching resistor in Engine Control Module (ECM) by measuring resistance between test box sockets 77 + 79. Specified value: 60-72 ohms If the resistance measurement is outside the specified range: - Replace Engine Control Module (ECM). See: Service and Repair If the resistance measurement is within the specified range: - Disconnect VAG1598/31 test box from Engine Control Module (ECM). - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Disconnect harness connector (arrow) from transmission control module. - Check CAN-Bus wiring for short to one another. Engine Controls - DTC's 00545/00638 Stored Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 93 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -8-. ^ Location: Behind rear section of molded headlining. Antennas All models use four antennas items -2-, 4- (qty. 2) & -7-. ^ Antennas (R130, R131) are integrated into rear hatch glass. ^ Antenna R11 in left rear side glass. ^ Antenna R93 in right rear side glass. Antenna amplifiers All models use four antenna amplifiers items -1-, -3-, -5- & -6-. ^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window. ^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid. ^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid. ^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window. Phaeton Page 4336 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times With Manufacturer's Scan Tool Air Flow Meter/Sensor: Testing and Inspection With Manufacturer's Scan Tool Mass Air Flow (MAF) sensor, checking NOTE: Only gold plated contacts can be used to repair terminals in the connector for the Mass Air Flow (MAF) sensor. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/22 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position (if equipped) - Coolant temperature at least 85 °C. See display group 04, display field 3. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -0- and -2- to input display group number 2 (002) and press -Q- button to confirm input. Indicated on display (1-4 = display fields) Read Measuring Value Block 2 -> 1234 Page 2051 a = dia. 33.5 mm b = max. allowable finishing measurement c = 2.0 mm - 2.5 mm If necessary, finish valve seat ring with 75° valve reseating tool Z = bottom edge of cylinder head 1:= 45° valve seat angle p = 30° correction angle upper = 73° correction angle lower Page 4125 Part 1 Page 673 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 2474 Radiator: Diagrams Cooling system components, body side Main radiator 1. Radiator 2. O-Ring 3. Upper coolant hose 4. Air scoop 5. 10Nm 6. Coolant fan (V7) 7. Fan bracket 8. Retaining clamp 9. Connector 10. Coolant fan (V35) 11. Bracket for fan connector 12. Lower coolant hose 13. O-Ring 14. Thermo switch (F18), 35 Nm for electric fan 15. Bracket for radiator 16. 15 Nm Page 5864 - Battery cell caps -2- covered with plastic foil. - Charge indicator -1- displays electrolyte level and charge condition. NOTE: - As the charge indicator is located in a single cell, the indication is only valid for that cell. An exact assessment of battery condition should always be confirmed by performing a load test. See: - If the charge indicator on batteries in excess of 5 years old are colorless, DO NOT attempt to top and/or recharge battery. Battery must be replaced. - Air bubbles that occur normally during battery charging (even during vehicle operation) may adversely affect charge indicator reading. To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock the vehicle in order to displace any possible air bubbles that have formed. Charge indicator, readings - Green -> sufficient charge (and electrolyte level) OK - Black -> no charge or insufficient charge - Colorless or yellow -> critically low electrolyte level. Top up with distilled water immediately. See: Electrolyte Level, Checking (Batteries With Charge Indicator) Visual check Always perform a visual check of the battery before checking no load voltage, electrolyte specific gravity and load test. Check for: - Cracked battery case and resulting corrosion damage to surrounding area. - Loose, damaged or corroded battery posts and terminals. WARNING! - Ensure that all battery post/terminal connections are securely installed and tightened according to the torque value specified. - Intermittent contact at battery terminals may spark or cause electrical system malfunctions. Maintenance Free Batteries, Checking Maintenance Free Batteries With Charge Indicator (magic Eye) Without Cell Caps, Checking Identification Page 3595 L4 Engine W/1 Exhaust Banks & 1 Catalysts Locations Steering Mounted Controls Communication Module: Locations J453 - Control module for multi-function steering wheel Page 308 Volkswagen Canada, Inc. With Manufacturer's Scan Tool Clutch Switch: Testing and Inspection With Manufacturer's Scan Tool Clutch Pedal Switch (Clutch Vacuum Vent Valve Switch -F36-) Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -6- and -6- to input display group number 66 (066) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 06 -> 1234 - Observe display in display field 2 (2nd digit from left). Specified value: x 0 x x - Depress clutch pedal fully and observe display in display field 2. Specified value: x 1 x x - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 4520 - Larger groove faces stator support 10. Housing for ATF pump 11. O-ring - Always replace 12. Torque converter oil seal - Removing and installing Fig. 1 Checking that the piston rings are correctly located - Ensure that ends of piston rings are hooked together. Fig. 2 Installing and hooking ends of piston ring together - Place piston ring in groove. - Press sides of ring in and guide ends over one another. Note: Do not twist piston ring out of groove on one side. Page 5278 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 5343 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 2498 Page 1475 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2131 9. 1.4 bar oil pressure switch (FI), 25 Nm - Black - If gasket is leaking, cut open and replace gasket Page 5616 ^ Turn ignition switch to "ON" position ^ On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button ^ Select "03 - Brake Electronics" ^ Select "07 - Code control unit" <-- Enter relevant code number for this vehicle when installing ABS control module 1C0 907 375 J ^ Press the "Q" button to confirm Note: On the display, in the upper right corner, the control module part number and coding are displayed ^ Press <-- button ^ Select "06 - End output" ^ Disconnect VAS 5051 from vehicle ^ Recode radio and reset radio preset stations ^ Reset clock ^ Where applicable, reset power window pinch protection ^ Turn ignition to "OFF" position ^ Proceed to Section E Section E Section E - Brake Bleeding ^ Connect brake charge and bleed unit US 1116 or VAS 5234 to vehicle IMPORTANT: When at least one chamber in the brake fluid reservoir is completely empty (e.g. leaks in braking system) the hydraulic unit must be bled with scan tool VAS 5051 or V.A.G. 1551 in function "basic setting". WARNING! Make sure that a filling pressure of 1 bar (14.5 psi.) is not exceeded, when filling brake fluid using brake filling and bleeding unit VAS 5234 or US 1116 Note: Page 2336 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1842 Fuse Block: Service and Repair Fuse Holder on Battery, Removing and Installing Fuse Holder On Battery, Removing And Installing NOTE: Obtain connector pin assignment from respective wiring diagram! Central Control Module For Comfort System Connectors Body Control Module: Locations Central Control Module For Comfort System Connectors Central control module for comfort system Page 6369 Installing - Place steering wheel - 1 - onto steering column. - The center markings on the steering wheel and steering column must align. - The coil connector mounting and pin must be positioned in the opening provided at the base of the steering wheel. - Fasten steering wheel with bolt -2-; torque is 55 Nm. - Mark bolt with punch indentation after each loosening procedure. Page 4435 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 2573 If after repairing other fault codes and setting readiness code, and any fault codes in the table return: Replace catalyst(s) as necessary, using applicable SRTs. If software updates do not apply, and only one or more of the following fault codes (DTCs) are present (see table): If DTC text indicates bank 2, bank 3, bank 4: Verify catalyst location before replacement, see Service Manual repair group 26. Use applicable SRTs. For technical assistance, select the "Technical Assistance" tab in ElsaWeb and follow the instructions to obtain a 6 digit pin. Tip: Before repairing vehicle or erasing fault codes (DTCs) remember to make print-outs including freeze-frame data as required and attach to the repair order. If catalytic converter is on parts submission, attach copies of all supporting documentation (including printouts) required when sending parts to Warranty Test Center. Page 6042 Power Distribution Relay: Locations Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 1642 8 - 6 Nm (53 in. lb) 9 - Filter element 10 - Air cleaner lower section 11 - Air duct 12 - 10 Nm (ft lb) 13 - O-ring Always replace if damaged 14 - Intake hose Ensure seated tightly - Press together at front to release - To Secondary Air Injection (AIR) pump motor -V101-: 15 - Connecting hose For crankcase breather - From breather housing on cylinder head cover 16 - Connecting hose Note installation position - From T-piece connection on intake manifold upper section /Evaporative Emissions (EVAP) canister purge regulator valve -N8017 - Positive Crankcase Ventilation (PVC) heating element -N79- For crankcase breather 18 - To throttle valve control module -J338-* Page 2450 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. Page 4370 - Place piston ring in groove. - Press sides of ring in and guide ends over one another. Note: Do not twist piston ring out of groove on one side. Fig. 4 Installing O-ring - Insert O-ring in recess in turbine shaft (arrow). Page 6359 - Displayed after pressing -C- button. Indicated on display: Read Measuring Value Block Help Enter display group number XXX - Enter display group number as needed. Evaluating Measured Value Blocks Display Groups, Interpreting Display group 001 Page 1244 Continuation If the specified value is not obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the valid safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions If the specified values are still not obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Evaluating display group 36, display field 1 - Lambda probe voltage Lambda probe after catalyst Possible causes of malfunction if 02S sensor control frequency is too slow: - The slots or holes in O2S sensor body are blocked - The O2S sensor vent hole in area of connecting wire is blocked - The O2S sensor has been overheated (glazed) Page 3221 ^ Check for DTC in the table shown. If DTC is listed in the table: The ECM hardware is not the cause of the DTC, further diagnosis is required. DO NOT replace an ECM for DTCs listed in the table. See "EXCEPTION!" notes following table Tip: If DTC is marked with an (*) it may require an ECM replacement to obtain the latest software: see "EXCEPTION!" notes following table. If DTC IS NOT listed in the following table: DTC should be properly diagnosed to determine the root cause (refer to Guided Fault Finding or Repair Manual as necessary). ALWAYS check for Technical Bulletins with possible software updates for the condition. Tip: This information applies to fault codes stored in addresses 01, 11 or Guided Fault Finding. Tip: EXCEPTION: For 1999 2001 New Beetle 1.8L Turbo (ONLY): For the following exceptions, first rule out other potential causes utilizing Repair Manual Information, Technical Bulletins or Guided Fault Finding before replacing ECM. Page 3505 - Disconnect 5-pin harness connector from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42- (arrow). - Connect multimeter to measure voltage on harness connector terminal -2- and engine Ground (GND). - Start engine and run at idle. Specified value: 11.0-15.0 V If no voltage is present: - Switch ignition off. - Check wire between 5-pin harness connector terminal -2- and Fuel Pump (FP) relay -J17- for open circuit according to wiring diagram. Wire resistance: max. 1.5 ohms If the voltage supply and wiring is OK: - Connect multimeter to measure voltage on harness connector terminal -4- and engine Ground (GND). - Switch ignition on. Specified value: min. 4.5 V If no voltage is present: - Switch ignition off. Page 695 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 1558 Specifications for front axle with front wheel drive 5) Camber corrections are not possible. Corrections are possible by moving the sub-frame slightly. Adjust approx 10' to 15' Specifications for rear axle, vehicles with front wheel drive Overview of work procedure for measuring vehicle The following work sequence of steps must be adhered to! - Check front axle camber and adjust if necessary. Adjusting camber, Refer to Alignment, Service and Repair, Camber. - Check rear axle camber. Camber is not adjustable, Notes, Refer to Alignment, Service and Repair,Camber on rear axle, adjusting - Check rear axle toe and adjust if necessary Refer to Alignment, Service and Repair,Toe on Rear axle, vehicles with front Wheel drive, adjusting Vehicles with front wheel drive The rear axle toe is not adjustable. Notes, Alignment, Service and Repair - Check front axle toe and adjust if necessary. Page 3727 Vehicle Speed Sensor: Locations Speedometer Vehicle Speed Sensor (VSS) (5 Spd. Manual Transmission) G22 - Speedometer Vehicle Speed Sensor (VSS) (5 spd. Manual transmission) Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module: Service and Repair Motronic ECM to Throttle Valve Control Module, Matching Engine Control Module (ECM) to Throttle Valve Control Module, Adaptation Adaptation teaches the Engine Control Module (ECM) (with ignition switched on and engine not running) the throttle valve control module stop positions and a comparison graph between throttle valve potentiometer and throttle position sensor. Adapting sequence must be performed if: - The voltage supply is interrupted - The throttle valve control module is removed and installed - The throttle valve control module is replaced - If when installing another engine another throttle valve control module is installed Special tools and equipment VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - No DTCs stored in DTC memory. - Battery (B+) voltage at least 11.5 V - All electrical consumers (e.g. lights and window defroster) switched off - Throttle valve must be at idle speed position Work sequence Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select data function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic Setting Input display group number XXX - Press buttons -0-, -6- and -0- to input display group number 60 (060) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 60 -> 1234 After pressing the -Q- button, the throttle valve position sensor is switched so that it is not supplied with voltage at the start of the test. In this condition the throttle valve is pulled into an emergency running position by a mechanical spring in the throttle valve control module. The values that both angle sensors provide in the emergency running position are stored by the Engine Control Module (ECM). Thereafter, the throttle valve is opened a predetermined value. If this value is achieved, the throttle valve is again switched so that it is not supplied with voltage. Now the mechanical spring must pull the throttle valve to the previously learned emergency running position within a predetermined period (spring test). Then the throttle valve is closed by the throttle valve positioner, and the values, which are supplied by the angle sensors in the throttle valve control module, are stored by the Engine Control Module (ECM). If the Engine Control Module (ECM) switches the throttle valve position sensor so that it is without voltage during normal operation, it is indicated by an increased and varying idle. The engine reacts slowly to accelerator changes. - Check specified values (display fields 1-4): Page 5713 Section A Section A - Check ABS Control Module Part Number - Connect VAS 5051 to data link connector located under the dash panel, outward of the steering column - Switch ignition to "ON" position - On the VAS 5051 Start-Up screen, press "Vehicle Self Diagnosis" button - Select "03 - Brake Electronics." - Read control module part number and code located in the upper right corner of the screen - If ABS control unit part number is 1C0 907 379 C, press (<) button, select "06 - End output", disconnect VAS 5051, turn ignition to "OFF" position and proceed to Section B - If ABS control unit part number is not 1C0 907 379 C no further work is required, press (<) button, select "06 - End output", disconnect VAS 5051 from vehicle and turn ignition to "OFF" position Section B Section B - Check ABS Control Module Supplier Code - Drive vehicle into hoist area - Raise vehicle on hoist Remove small grommet -large arrow- for the ABS wheel speed sensor wire in the left front wheel housing NOTE: Tire and wheel removal is not necessary - Read supplier code -small arrow- (circled for illustration purposes only) of the ABS control module through the opening NOTE: The label showing supplier code is upside down in vehicle - If the ABS control module has part number 1C0 907 379 C and has supplier code 0321.3, the ABS control module must be replaced. Reinstall rubber grommet and proceed to Section C - If the ABS control module has part number 1C0 907 379 C and does not have supplier code 0321.3, no further work is required. Reinstall rubber grommet and lower vehicle on hoist Section C Section C - ABS Control Module Removal and Installation - Obtain radio code and record radio preset stations - Turn Ignition Switch to "OFF" position Relay Locations Compiled From Every Wiring Section 1998-2004 Daytime Running Lamp Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 840 Cruise Control Switch: Diagrams Cruise Control Switch D - Connector, 10 pin 1 - Open 2 - Switch for CCS - On / Off 3 - Switch for CCS - Set / delay 4 - Switch for CCS - Reset / Resume saved speed / Accelerate 5 - Switch for CCS - Reset / Resume saved speed / Accelerate 6 - Switch for CCS - On / Off 7 - Switch for CCS 8 - 10: Open Page 5272 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 5039 1 - Internal puller Kukko 21/3 1. Selector shaft - Revised stop sleeves, which allow the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of transmission build date 04 090 Refer to Fig.4 2. Stop ring 3. Ball sleeve - Removing Refer to Fig. 1 - Pressing in Refer to Fig. 2 4. Selector mechanism cover - With an additional bolt which allows the selector shaft to be guided into the 4th gear gate when changing down from 5th to 4th gear, have been introduced as of transmission build date 04 09 0 Refer to Fig. 4 5. Reverse light switch, 20 Nm - Lightly coat lug with MoS2 grease 6. Cap - For transmission breather 7. Relay lever - Installation position 8. Bushing 9. Oil seal - Pry out with screwdriver - Installing Refer to Fig. 3 10. Circlip 11. Hex nut, 20 Nm - Self-locking Page 2574 Warranty Required Parts and Tools When replacing any catalyst, your VIN may be required to ensure the correct part is ordered (check with your parts department). No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3488 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Coding Engine Control Module (ECM), Coding NOTE: - A 5-character code must always be displayed during the control module identification. - The control module must be recorded if the vehicle relevant coding is not displayed or the control module has been replaced. Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -7- to select "Code Control Module" function 07 and press -Q- button to confirm input. Indicated on display Code Control Module Enter code number XXXXX (32000) - Enter relevant code number for vehicle and press -Q- button to confirm input. Coding variants: Coding Vehicle 00031 Manual Transmission 00033 Automatic Transmission The control module identification and coding are indicated on the display, (example) 0219060186 MOTRONIC ME7.1G V06 -> Coding 00000 WSC 00000 Indicated on display when a non-authorized code number has been entered Function is unknown or -> cannot be carried out at the moment. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. NOTE: The code entered and shown on the display will not be used by the Motronic control module until the ignition has been switched off once. An incorrect coding leads to: - Engine running malfunctions (rough gear changes, load change jerks, etc.). - Increased fuel consumption. - Increased exhaust gas emissions. - Malfunctions stored in DTC memory which are not actually present. - Functions will not be performed (Oxygen Sensor (O2S) control, activation of the EVAP system, etc.). - On front wheel drive vehicles the traction control will not function (TC warning lamp comes on). Page 638 40 - Multi-Function TR Switch -F125- (pin 2) 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 1754 Pe-Ca A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 4839 6. Hex nut, 20 Nm 7. Dished washer 8. Lever - For selector shaft 9. Bolt, 6 Nm 10. Multifunction switch -F125 - Removing, installing, adjusting - Tested in the vehicle by On Board Diagnostic (OBD) 11. Securing clip - For wiring harness to transmission housing 12. Wiring harness - For solenoid valves and transmission sensors 13. O-ring - Always replace - For connector/wiring harness 14. O-ring - Always replace - Removing and installing 15. O-ring - Always replace - Removing and installing 16. Valve body - Removing and installing - Designation of solenoid valves = Fig. 2 17. Cap - To secure level plug after checking ATF level - Always replace 18. Plug 19. O-ring - Always replace 20. Breather cap 21. Bolt, 8 Nm 22. Valve body cover - Removing and installing 23. Bolt, 8 Nm - Observe assembly sequence 24. Wiring harness - For transmission sensors 25. Manual valve - Secure against falling out when removing valve body Fig. 1 Replacing drain plug seal - Cut open seal -arrow- with side cutting pliers; always replace seal. - Following repair work, install new seal to plug and screw in hand-tight to fill with ATF. - Fill transmission with ATF; check ATF level and top up if necessary. Page 4861 9. Bracket - Secured to body work 10. Dust cap 11. Bleeder valve - Bleeding clutch system. 12. Slave cylinder Remove the following components before removing slave cylinder Gear selector cable from gear selector lever. - Relay lever and actuating arm for gate selector cable. After installing: Adjust gear selector mechanism. 13. Collared securing bolt, 25 Nm 14. Transmission 15. Clip 16. Seal - Lubricate with brake fluid - Pull onto line/hose connection 17. Cable support bracket 18. Hose bracket Secure to control cable support bracket 19. Clip Fig. 1 Pry retainer -A- off in direction of arrow Fig. 2 Press master cylinder operating rod into retainer -A- in direction of arrow Page 5443 ^ Re-connect electrical connector for hydraulic pump motor. ^ Install ABS unit to bracket. Note: Hand-tighten bolts at first to make attaching the individual brake lines easier. ^ After tightening brake lines, tighten hydraulic unit. ^ Continue installation in reverse order of removal. ^ Bleed brake system ^ Enter radio code. ^ Code control module. Tightening Torques: Control module to hydraulic unit - maximum 4 Nm (35 inch lbs.) Hydraulic unit to bracket - 8 Nm (70 inch lbs.) Nut for brake master cylinder to brake booster - 20 Nm (15 ft. lbs.) Brake lines at ABS unit: Thread M10 x 1 - 14 Nm (10 ft. lbs.) Thread M12 x 1 - 14 Nm (10 ft. lbs.) Nut to body - 20 Nm (15 ft. lbs.) Cap nut to body - 20 Nm (15 ft. lbs.) Page 5695 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Intake Air Temperature Sensor - Climate Control Ambient Temperature Sensor / Switch HVAC: Description and Operation Intake Air Temperature Sensor - Climate Control Fresh air intake duct temperature sensor -G89Function: Temperature sensor controls temperature flap and fresh air blower depending on temperature. In event of malfunction: outside temperature sensor -G17- value is used instead. Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Page 1197 Engine Speed Sensor: Testing and Inspection With Generic Scan Tool Check Engine Speed (RPM) Sensor Function The Engine Speed (RPM) Sensor -G28- detects engine speed and reference marks. Without an engine speed signal, the engine will not start. If the engine speed signal fails while the engine is running, the engine will stop immediately. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test sequence Vehicles with engine code AFP - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Vehicles with engine code BDF - Disconnect gray 3-pin harness connector (arrow) to the engine speed (RPM) sensor. Continuation for all vehicles Cooling System - Coolant Identification/Mixing Coolant: Technical Service Bulletins Cooling System - Coolant Identification/Mixing 19 10 03 March 18, 2010 2022548 Supersedes T.B. Group 19 number 10-02 dated March 17, 2010 to improve coolant table view. Condition Identifying and Mixing Factory Fill Engine Coolants Discontinuation and mixing of Volkswagen approved engine coolants. Technical Background Coolants G11, G12 and G12+ have been replaced by an improved version. New coolant G12++ will be introduced on all engines. Production Solution No production change required. Service. Identify which coolant the vehicle was filled with from the factory. The photo shows the color of each type of engine coolant. The table identifies which coolant can be added to the factory coolant. Tip: If a vehicle is found to have the incorrect coolant, the cooling system should be flushed using the repair manual procedures in Elsa Web and then filled with the correct coolant. Page 2590 Display Fields If the indicator does not behave as described: - Press - button. - Check DTC memory. If the indicator behaves as described: Release brake pedal. If "Cat B1 OK" is displayed in field 4: Check DTC memory. - Read-out readiness code. - If fault memory was erased or engine control unit was separated from positive voltage supply, readiness code must be regenerated. Locations Shift Interlock Solenoid: Locations N110 - Shift lock solenoid Page 2211 1) Timing Chain Upper Guard Rail. 2) Camshaft Sprockets 3) Shutter Wheel 4) Timing Chain Upper Tensioner Rail. NOTE: If TDC Cyl. 1 position is correct, it will be possible to see a slot - arrow - on the sprockets of the intermediate shaft. If the groove cannot be seen: Turn crankshaft one turn further in direction of rotation of engine. Page 2230 - Align camshafts with camshaft guide 3268. - Prepare cylinder head gasket for assembly. - Install cylinder head. - Push sliding rail onto bearing bolt. Insert short mounting bolt with "D6" locking compound and tighten both bolts to 20 Nm. - Mount camshaft sprocket with camshaft roller chain to camshaft for cylinder bank 1, 3, and 5 (long camshaft) and turn in opposite direction by hand. - Mount camshaft sprocket (with pickup wheel for Hall generator) and camshaft roller chain to camshaft for cylinder bank 2, 4, and 6 and turn in opposite direction by hand. Note: Coat contact surfaces of the bolt heads with oil when installing. - Remove camshaft guide 3268. - Tighten mounting bolts for camshaft sprockets to 100 Nm. Note: Hold camshaft - arrow - only with open-end wrench SW 24. The camshaft guide 3268 must not be inserted when tightening or loosening the sprockets. - Coat sealing surface of sealing flange with AMV 188 001 02. - Coat O-ring for oil passage seal and insert in cover piece. Page 1821 Part 1 Page 2099 Warranty Required Parts and Tools Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 1273 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor Before TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control Before TWC, Checking, With Manufacturer's Scan Tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control Before TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Before Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Heated Oxygen Sensor (HO2S) -G39- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 6-pin harness connector (black) -1- to Heated Oxygen Sensor (HO2S) -G39- before catalytic converter. Page 5293 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 2858 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Remove protective cover (arrows) and disconnect 6-pin harness connector (black) -1- from Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC). - Check wiring for open circuit between test box and 6-pin harness connector (to control module) according to wiring diagram. Terminal -1- + socket 70 - Terminal -2- + socket 71 - Terminal -5- + socket 51 - Terminal -6- + socket 52 - Wire resistance: Max. 1.5 ohms Page 6430 ^ Can be replaced individually ^ Checking shock absorber for leaks and noises ^ Disposal -follow environmental codes 13. Buffer stop 14. Protective sleeve Suspension Strut Removal and Installation Removing - Remove wheel. - Remove bolts -2- from brake caliper. - Remove brake caliper and hang or secure on body. Do not hang from brake hose. - Remove coupling link from control arm. - Release speed sensor wiring from suspension strut. Right suspension strut NOTE: If right suspension strut is to be removed additional work is required - Remove noise insulation. - Disconnect axle shaft from transmission drive flange. Following work sequence applies to both sides - Remove bolt and separate wheel bearing housing/suspension connection. Page 3171 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Connect multimeter to measure voltage at terminals -2- and -6-. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. - Connect multimeter to measure voltage at harness connector terminal -2- and Ground. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. Page 181 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Locations Shift Interlock Solenoid: Locations N110 - Shift lock solenoid Page 1583 NOTE: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator: - Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. - Switch ignition off. - Now check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow -arrow-). - Observe pressure drop on pressure gauge. If pressure does not drop: - Test check-valve of Fuel Pump (FP), Fuel Pump (FP), checking. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking If pressure does drop again: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator: Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. If pressure does drop again: - Check whether line connections, O-rings in fuel rail, and fuel injectors are properly sealed. - Check whether pressure gauge is properly sealed. NOTE: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. Page 443 Power Distribution Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 1758 Bu-Ch Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Frost Protection to: Antifreeze: G12* Water* -25°C 40% 2.7 Liters 3.6 Liters -35°C 50% 3.0 Liters 3.0 Liters * The amount of coolant can vary depending on vehicle equipment. Locations Valve Body: Locations 4 Speed Automatic 01M Valve Body Location: above oil pan. The solenoid valves -N88-, -N89-, -N90-, -N91-, -N92-, - N93- and -N94are attached to the valve body. Page 1259 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the oxygen sensor control in display field 1 does not fluctuate as stated: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Carry out road test to remove possible residue on oxygen sensor and repeat check. Observe the safety precautions when carrying out a road test. Refer to "Fuel Delivery and Air Induction", See: Powertrain Management/Fuel Delivery and Air Induction/Service Precautions If the specified values in display field 1 are not obtained even after a road test or the value does not fluctuate by at least 2 %: - Check oxygen sensor (before Three Way Catalytic Converter (TWC)) aging. Evaluating display field 32, display field 1: Oxygen sensor learned values before Three Way Catalytic Converter (TWC) Front Wheel Bearing: Service and Repair Front Wheel Bearing, Servicing II - Wheel bearing, servicing Special tools, testers and auxiliary items required ^ Thrust plate VW401 ^ Punch VW407 ^ Punch VW408A ^ Punch VW412 ^ Thrust tube VW432 ^ Thrust tube VW442 Page 2334 Part 2 Service and Repair Oil Filter Housing: Service and Repair Oil filter housing, disassembling and assembling 1. Gasket - Always replace - Observe correct fitting position - Lubricate before assembly 2. Filter housing 3. Stop - For oil cooler - Fastened to the oil filter housing 4. Filter cartridge - Maintain regular change intervals - With by-pass valve. Opening pressure: 2.0 bar - Clip into bottom of oil filter before installing 5. O-Ring - Always replace - Lubricate before assembly 6. Bottom of oil filter housing, 30 Nm - Empty before disassembling 7. Oil drain plug, 10 Nm 8. 25 Nm Page 2840 Display Group 036 If the specified value is obtained: - Release brake pedal. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Relay Locations Compiled From Every Wiring Section 1998-2004 Fog/Driving Lamp Relay: Locations Relay Locations Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 60 Section 2 - Radio antenna system diagnosis through radio unit Premium VI radios are capable of signal diagnosis through operating internal diagnostics of the radio unit. All models except Touareg and Phaeton: - Select AM or FM. - Press and hold the mix button (black arrow). - Screen will appear that shows "Service Test mode" (white arrow). - Press mix button briefly. ^ Test one indicates current antenna status, i.e. ON or OFF (arrow). - Press mix button briefly again. Page 2410 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 5839 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1762 No-Po Service and Repair Seals and Gaskets: Service and Repair For further information regarding this components and the system that it is a part of, please refer to Manual Transmission/Transaxle; Service and Repair. Page 6548 Air Door Cable: Service and Repair Central Flap Cable, Installing and Adjusting Cables, Installing And Adjusting Central flap cable, installing and adjusting Prerequisites: - Central flap lever correctly adjusted, See Fig. 1 - Heating and ventilation controls are installed. Connecting duct removed. Adjusting - Turn air distribution rotary control knob to left onto stop. - Attach center wire of cable -2- to central flap lever -1-. - Push central flap lever to stop -arrow A- and attach outer cable -2- with clip -3-. Turn air distribution rotary control knob to left and right onto stops. - When turning the rotary control knob both end stops must be reached. Page 3543 Scale A shows resistance values for temperature range 0-50 °C and scale B shows the values for temperature range 50-100 °C. Examples: 30 °C corresponds to a resistance from 1500-2000 ohms - 80 °C corresponds to a resistance from 275-375 ohms If the specified value is not obtained: - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2- item 23. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If there is no malfunction in the wiring and the resistance measurement values are OK: - Replace Engine Control Module (ECM). Page 4870 Pedal Cluster, Assembly Overview 1. Bulkhead - With provision for mounting bracket and master cylinder 2. Seal - Always replace 3. Mounting bracket - For mounting clutch pedal 4. Bolt 5. Mounting bracket - For mounting accelerator and brake pedals 6. Self-locking hexagon nut, 25 Nm (18 ft. lbs.) - Always replace 7. Connecting plate 8. Self-locking hexagon nut, 25 Nm (18 ft. lbs.) - Always replace 9. Bushing 10. Fulcrum pin 11. Clutch pedal - Removing and installing. 12. Retainer - Removing and installing. 13. Self-locking hexagon nut, 25 Nm (18 ft. lbs.) - Always replace Testing and Inspection Valve Guide: Testing and Inspection Valve guides, checking Special tools, equipment, test and inspection devices; required accessories: Universal gauge retainer VW 387 - Gauge Test procedure - Insert a new valve into guide. Valve stem end must be flush with guide. Because of varying stem diameters, use only intake valves in intake guides and exhaust valves in exhaust guides. - Determine tilt clearance. Max. wear: Intake valve guide = 1.0 mm - Exhaust valve guide = 1.3 mm Page 5437 Hydraulic Control Assembly - Antilock Brakes: Locations Note: Complete brake master cylinders and brake boosters can be replaced separately. 1 Brake Booster ^ For gasoline engines vacuum is taken from the intake manifold ^ Diesel engines have a vacuum pump to create the required vacuum ^ Functional check: With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in the unit) - Hold brake pedal with average foot pressure in brake position and start engine. If brake booster is functioning properly, brake pedal should give noticeably underfoot. ^ If pedal does not give, replace brake booster ^ Check valve (in vacuum hose) Functional check ^ Separating from brake pedal. 2 Cap 3 Brake fluid reservoir 4 Plug ^ Coat with brake fluid and press into reservoir 5 Retaining pin ^ Insert through brake master cylinder 6 Brake master cylinder ^ Cannot be repaired. If faulty, replace as complete unit 7 Hex nut, self locking 20 Nm (15 ft. lbs.) 8 Bolt, 8 Nm (70 inch lbs.) 9 Cap nut, 20 Nm (15 ft. lbs.) 10 ABS/EDL hydraulic unit 11 ABS control module Page 3943 Fuel Pressure: Testing and Inspection Fuel Pressure Regulator and Residual Pressure, Checking Fuel Pressure Regulator And Residual Pressure, Checking Function The fuel pressure regulator controls the fuel pressure as a function of the Manifold Absolute Pressure (MAP). The specified value for this test is dependent on the working pressure of the Fuel Pump (FP). This is about 3.0 bar positive pressure Recommended special tools and equipment - V.A.G 1318 pressure gauge - VAG1318/10 adapter - VAG1318/11 adapter - VAG1318/16 hose adapter - VAS5024 assembly tool for spring-type clamps Test requirements - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Delivery quantity of Fuel Pump (FP) OK, Fuel Pump (FP), checking. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking Test sequence WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection. Vehicles with engine code AFP Page 4572 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 2222 NOTE: U-clip may be used during installation to prevent extension of tensioner. Remove clip after positioning. - Lock vibration damper in position with locking bracket 3406. Page 6493 Special tools, testers and auxiliary items required ^ Thrust pad VW447 1 ^ Pressing appliance VW459/2 ^ Thrust pad 40 - 105 ^ Box wrench SW 32 3252 A ^ Assembly tool 3253 ^ Collar for wheel bearing inner race 3423 Page 3533 Continuation for all vehicles - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4239 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4986 ^ Remove transmission drain plug -1- and bearing pin -2-, allow transmission to totally drain. ^ Install bearing pin -2- using new grommet. ^ Install drain plug -1-. ^ Turn bracket -A- back to original position so the selector shaft -1- can move freely. Transmission, filling: ^ ADD new transmission oil Part No. G 055 726 A2 to oil already in catch container until total volume is 1.9L (2 qt.). ^ Remove back up light switch arrow -1-. ^ Connect a rubber hose (approx. 600 mm (24 in.) long with a 10 mm (3/8 in.) diameter) to a funnel. ^ Insert hose into hole of back up light switch and fill transmission. ^ Install back up light switch. ^ Check the operation of shifter. install air filter housing. ^ Install sound insulation. 02J Manual 5 Speed Transmission, Draining and Re-filling See Repair Manual Group 34, Manual Transmission - Controls, Housing. Page 3653 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Load Reduction Relay Power Distribution Relay: Locations Load Reduction Relay RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Engine Controls - DTC's 00545/00638 Stored PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 5940 Warranty NOTE: For model years 2007 (after published VIN range) and newer, this is not a warrantable issue. Please consider this publication as information only. Required Parts and Tools No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3246 Select function XX NOTE: The next time the ignition is switched "on" the identification of the engine control module is read by the immobilizer control module and stored. Page 4411 Test Step 1 - 2 Page 866 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping Page 2526 Display Group 4 If the specified value is not obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Replace Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-, item 23. NOTE: The temperature rises in steps of 1.0 °C. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. 4 Speed Automatic 01M Shift Cable: Service and Repair 4 Speed Automatic 01M Selector lever cable, removing and installing Removing Shift selector lever into "P" position. - Pull selector lever cable upward off lever/selector shaft -4-. - Raise vehicle. - Separate exhaust system by loosening clamping sleeve. - Remove tunnel heat shield front and rear. - Remove cover from selector lever housing. - Pry selector lever cable -3- off selector lever -2- with a screwdriver. - Pull circlip -1- for securing selector lever cable to selector lever housing out downward. - Pull selector cable carefully out of selector lever housing. Installing Note: Check the protective sleeve for damage; the protective sleeve can only be changed together with the selector lever cable. - Before installing lightly grease ball socket on end of cable. - Check that the protective sleeve correctly fitted. Do not install the protective sleeve twisted. - Do not bend or kink the selector lever cable. - Selector lever and lever/selector shaft are in "P" position, front wheels are blocked. Page 1895 Special tools, testers and auxiliary items required ^ Thrust pad VW447 1 ^ Pressing appliance VW459/2 ^ Thrust pad 40 - 105 ^ Box wrench SW 32 3252 A ^ Assembly tool 3253 ^ Collar for wheel bearing inner race 3423 Page 5187 Part 2 Page 1185 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 4238 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 3609 - Connect multimeter for voltage measurement to terminals 3 + 4 of connector to Engine Control Module (ECM) and measure primary voltage. Specified value: 0.40 to 0.50 Volts - Switch ignition off. If specified value is not obtained: - Test oxygen sensor wires. If specified value is obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- Bank 1: Vehicles with engine code AFP, item 9, - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. - Check wires between test box and 4-pin connector (to control module) for open circuit according to wiring diagram. Page 6508 - Drive in dust cap. Note: ^ Always replace dust caps. ^ Damaged (dented) dust caps allow ingress of moisture, always use the tool illustrated. Always use tool illustrated to reduce chance of damage to dust cap. Further installation in reverse order Install and fasten wheel. Fastener/location Tightening torque: Brake caliper to rear axle .............................................................................................................................................................. 65 Nm (48 ft. lbs.) Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Wheel Bearing/Wheel Hub on Vehicles With Drum Brakes, Removing and Installing Special tools, testers and auxiliary items required ^ Hub cap puller VW637/2 Page 4657 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 1866 - Install the central console cover. Page 455 Relay Box: Application and ID Relay and Fuse Arrangements Relay Arrangements On The Relay Panel Relay and fuse arrangements Page 2714 Display Group 060 - Terminate engine basic setting at earliest after 30 seconds by pressing -> button. Adaptation has been performed successfully. To store the values: A/T - Slips On 2-3 Upshift Control Module: Customer Interest A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Interior - Rattles Near Center Air Outlet Air Register: All Technical Service Bulletins Interior - Rattles Near Center Air Outlet Group: 80 Number: 04-01 Date: Aug. 5, 2004 Subject: Dash Panel, Rattles Near Center Air Outlet Model(s): Jetta 1999 --> 2004 see VIN Below Condition Rattles near center air outlet of dash panel, when driving over rough roads. Production As of VIN: 3VWRA69M74M133075, two felt strips (12 mm X 15 mm X 1 mm) have been installed where the center air outlet slides into the air duct. Service For vehicles prior to 3VWRA69M74M133075: - Remove center air outlet (see Repair Manual Repair Group 80 - Heating, Ventilation Air outlets, removing Center air outlet (Jetta), removing). With air outlet removed: - Cut two pieces of adhesive backed felt (12 mm X 15 mm) using Part No: 191 861 390D. Note: Part Number can be used for approx. 2.5 vehicles. CAUTION! Part numbers listed in this Technical Bulletin are for reference only. Always check with your Parts Dept. for the latest parts information. M/T - Humming Noise When Turning at Low Speeds Fluid - M/T: Customer Interest M/T - Humming Noise When Turning at Low Speeds 34 06 02 June 12, 2006 2011899 Affected Vehicles Supersedes TB Group 34 number 06-01 dated June 5, 2006 due to Golf model Condition Customer States Humming Sound From Front of Vehicle During Cornering Customer may state humming sound coming from front of vehicle on turns in vehicles equipped with 02J or 0A4 manual 5 speed transmission. The hum may be more noticeable during slow speed turning maneuvers with steering wheel almost to full travel. The hum diminishes with steering wheel straight. Technical Background Hum may be generated by the differential spider gear contacting the one piece thrust washer when under load. Production Solution New transmission oil Part No. G 055 726 A2 incorporated in transmission production plant. Transmissions with new oil installed begin with VINs in table. Service 0A4 Manual 5 Speed Transmission, Draining and Re-filling If the vehicle exhibits this condition, drain and re-fill transmission as follows: - It is no longer possible to accurately check transmission oil level in the same manner as previous model years. Page 6438 If piston rod does not return to starting position and there is no loss of oil, shock absorber is OK. 2. Protective cap 3. Protective tube 4. Stop buffer 5. Shock absorber bushing 6. Selflocking nut ^ 25 Nm (18 ft. lbs.) ^ Removing see Fig. 1 ^ Always replace 7. Cover Special tools and equipment ^ T10001 Shock absorber tool set Fig. 1 Shock absorber nut, removing 1. Ratchet handle, locally available 2. T10001/9 Socket 3. T10001/11 4-T10001/1 Socket Page 4524 1. Bolt, 4 Nm 2. Manual selector valve control - Adjusting, Removing and Installing, refer to Valve Body; Service and Repair. 3. Selector shaft with selector segment - Removing and installing see Fig. 2 4. Spring pin - Driving out and in see Fig. 1 5. Engaging lever - Insert together with selector shaft and detent segment 6. Detent segment - Insert together with selector shaft and engaging lever 7. Locking washer 8. Bolt, 10 Nm 9. Spring for selector segment 10. Bolt, 10 Nm 11. O-ring - Always replace - Only install on shafts with groove for circlip 12. Washer 13. Shaft for detent lever - Is secured by circlip and bearing cap of drive pinion 14. Return spring - Inserting see Fig. 4 15. Detent lever - Inserting with return spring see Fig. 4 16. Parking lock gear - Rounded side faces teeth of drive pinion Page 2277 NOTE: If fuel should escape at the vacuum connection of the pressure regulator, replace fuel pressure regulator: - Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. - Switch ignition off. - Now check for proper seal and residual pressure. Observe pressure drop on pressure gauge for this. After 10 minutes at least 2.0 bar positive pressure should still be present. If residual pressure falls below 2 bar positive pressure: - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously close shut-off valve of pressure gauge (lever perpendicular to direction of flow -arrow-). - Observe pressure drop on pressure gauge. If pressure does not drop: - Test check-valve of Fuel Pump (FP), Fuel Pump (FP), checking. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump, Checking If pressure does drop again: - Open stop valve of pressure gauge (lever in direction of flow -arrow-). - Start engine and let run at idle. - Wait until pressure has risen, and then switch off ignition. Simultaneously pinch return hose tightly together. If pressure does not drop: - Replace fuel pressure regulator: Vehicles with engine code AFP, item 15, - Vehicles with engine code BDF, item 11. If pressure does drop again: - Check whether line connections, O-rings in fuel rail, and fuel injectors are properly sealed. - Check whether pressure gauge is properly sealed. NOTE: Before removing pressure gauge, put cleaning rags back around line connection which is to be disconnected. Locations Clutch Switch: Locations F194 - Clutch Pedal Position (CPP) switch A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: All Technical Service Bulletins A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. Page 5136 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 6305 - Remove cover -A-. - Remove steering joint bolt. - Pull universal joint off steering gear. - Clamp hose from reservoir with hose clamp 3094. Page 1298 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6418 ^ 3256 Counterhold Removing and installing only possible with subframe removed. Bonded rubber bushing, pressing out Bonded rubber bushing, pressing in NOTE: ^ To aid pressing in use light oil ^ Never use grease! Page 6054 Power Distribution Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 3038 A/C Signal: Testing and Inspection Not Available For Generic Scan Tool The manufacturer does not provide this procedure using a generic scan tool. Page 3619 - Additionally, check wires all for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Heater Check Heated Oxygen Sensor (HO2S) -G39- Before Three Way Catalytic Converter (TWC), Checking NOTE: Only gold plated terminals may be used to repair the contacts in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display Read Measuring Value Block Input display group number XXX Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 5524 ^ Remove bolts from brake caliper housing by counter-holding on guide pins. ^ Remove brake caliper housing and suspend with wire so that weight of caliper does not stress or damage brake hose. ^ Remove brake pads and pad retaining springs (arrows). ^ Clean brake caliper housing, especially bonding surface for brake pad. Bonding surfaces must be free of adhesive and grease residues. Installing Before pressing the piston back, draw off brake fluid from the reservoir. Use a bleeder bottle a plastic bottle which is only used for brake fluid. Brake fluid is poisonous and must on no account be sucked out by mouth through a hose. ^ Screw in piston by turning knurled wheel of special tool 3272 clockwise. Notes: ^ Install special tool 3272 with the collar (arrow) of the tool seated on the brake caliper. ^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow -A-) provided for this purpose. ^ If the piston is pushed back with a piston resetting tool the automatic adjustment in the brake caliper will be destroyed. ^ Pull protective foil off outer brake pad backplate. Page 4216 Part 2 Page 5724 Owner Letter Page 4406 - Remove wiper arms. - Switch ignition off, open hood Removing plenum water tray cover - Unclip trim -1- from inner side offender in area of hood hinge -2- on right and left sides. - Remove entire length of plenum seal -1- and remove screws -2-. - Remove cover for pollen filter -3- by pulling cover forward and up. - Push plenum water tray cover -1- upward off of seat at base of windshield -2- and remove. Page 4844 - Move selector shaft with detent segment -1 in position "2". - Insert new O-rings -arrows- in transmission housing. Note: Ensure that O-rings remain seated correctly when installing valve body. - Install valve body so that pin of detent segment engages in groove of manual valve -1-. Only the end of the manual valve is visible. The groove on the valve cannot be seen. Check operation of manual valve. - Tighten valve body bolts (arrows) by hand. - Tighten bolts to 8 Nm working from inside outward. - Clip transmission sensor wiring harness -3- into retaining tabs -4- installed for this purpose. - Join connectors -1- and -2-. Page 4400 Test Step 1 Page 2906 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Page 6461 - Pull off wheel bearing/wheel hub unit from stub axle. A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Note: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 . Page 6190 Relay Box: Locations Relay Positions Compiled From Every Wiring Section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 4665 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 6510 - Pull off wheel bearing/wheel hub unit from stub axle. A - Puller with leg clamp, e.g. Kukko 20/2 - Pull off bearing inner race from stub axle. - Only use puller - A - with leg clamp e.g. Kukko 204-2 (commercial type). Installing - Install wheel bearing/wheel hub unit as far as possible on stub axle. - Attach special tool 3420 and pull wheel bearing/wheel hub unit on to stop. Note: Make sure that the hubs/wheel bearing unit does not tilt! - Remove assembly tool 3420 . Page 6022 23 - Parking & sidemarker lights, left 5A 24 - Windshield and rear window washer pump, winshield wiper motor 20A 25 - Fresh air blower, cimatronic, air conditioning 25A 26 - Rear window defogger 25A 27 - Motor for rear windshield wiper 15A 28 - Fuel pump (FP) 15A 29 - Engine control module (ECM), gasoline 15A - Engine control module (ECM), diesel 10A 30 - Sunroof 20A 31 - Automatic transmission 20A 32 - Engine control, injectors, gasoline 10A - Engine control module (ECM), diesel 15A 33 - Headlight washer system 20A 34 - Engine control elements 10A 35 - 12V power outlet (in luggage compartment) 30A 36 - Fog lights 15A 37 - Terminal (86S) on radio, instrument cluster 10A 38 - Central locking system (with power windows), luggage compartment light, remote/fuel tank door, motor to unlock rear lid 15A 39 - Emergency flasher system 15A 40 - Dual horn 20A 41 - Cigarette lighter 15A 42 - Radio system 25A 43 - Engine control elements 10A 44 - Heated seats 15A Page 4450 - Indicated on display: ‹› Press buttons -0- and -8-. (Function "Read measured value block" is selected with -08-). - Indicated on display: ‹› Confirm entry with Q button. - Indicated on display: ‹› Press buttons-0--0--5-. (-005- selects the "Display group number -005-"). ‹› Confirm entry with 0 button. - Indicated on display: ‹› First display zone shows ATF temperature. - Bring ATF to test temperature. ‹› Test temperature: 35° C to 45 °C (95 to 113° F). - Remove ATF level plug from oil pan. - ATF in overflow line runs out. - If ATF drips out of hole: ‹› ATF need not be topped up. - Install new seal (arrow 1) on plug and tighten to 15 Nm (11 ft.lb). ATF check is completed. - Plug (arrow 3) and cap (arrow 4) remain closed. Page 804 A/C Pressure Sensor/Switch - Cooling Fan: Description and Operation High Pressure Sensor G65 High Pressure Sensor G65 Where applicable, High Pressure Sensor G65 transmits a square wave signal to Coolant Fan Control (FC) Control Module J293 at a rate which varies according to the refrigerant system pressure. J293 reacts to the pulse rate of the signal from G65 as follows: If the refrigerant system pressure rises, J293 switches the radiator fan(s) to the second speed. - Where excessive or insufficient refrigerant system pressure is present (E.g.: insufficient air flow over condenser or when overcharged), Coolant Fan Control (FC) Control Module J293 switches the A/C Clutch N25. - On Climatronic equipped models it informs the A/C Display Control Head E87 that the pressure in the refrigerant system is OK and that A/C Clutch N25 can be switched on via J293). On applicable engines, the signal generated by G65 is also provided as an input to the Motronic Engine Control Module (ECM). As the amount of torque needed to drive the A/C compressor varies according to the refrigerant system pressure, the ECM processes this signal in order to enhance engine performance. Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of G65 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Page 220 2010421 Supersedes Technical Bulletin Group 60 number 07-05 dated May 31, 2007 due to removal of Jetta Wagon (A5) Models and reformatting of flowcharts. Condition Page 2494 Part 1 Page 4241 Transmission Speed Sensor: Service and Repair 4 Speed Automatic 01M Transmission Vehicle Speed Sensor -G38Removing and installing -G38- Switch ignition off. - Disconnect connector from sensor. - Remove bolt and take sensor out. - Replace seal. Installation is performed in the reverse order of removal. - Tighten bolt to 10 Nm (7 ft lb). With Manufacturer's Scan Tool Camshaft Position Sensor: Testing and Inspection With Manufacturer's Scan Tool Camshaft Position (CMP) Sensor -G40-, Checking NOTE: Only gold-plated contacts must be used to repair the contacts in the Camshaft Position (CMP) sensor -G40- harness connector. Special tools and equipment - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - Camshaft Position (CMP) sensor -G40- screwed on tight - Battery (B+) voltage at least 11.5 V Test sequence - Disconnect 3-pin harness connector from Camshaft Position (CMP) sensor -G40- (arrow). - Connect multimeter to measure voltage with adapter cables from VW1594 to terminals 1 (B+) and 3 (GND) on Camshaft Position (CMP) sensor -G40- harness connector. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. If no voltage is present: - Remove wiper arms and plenum chamber cover. Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Page 3416 - Disconnect 6-pin harness connector from throttle valve control module (arrow). - Connect multimeter to measure voltage at terminals -2- and -6-. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. - Connect multimeter to measure voltage at harness connector terminal -2- and Ground. - Switch ignition on. Specified value: min. 4.5 V - Switch ignition off. Page 4762 - 3094 Hose clamps - V.A.G 1331 Torque wrench or equivalent Removing ATF cooler - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Remove cover from engine. - Switched ignition off and disconnect the battery Ground strap. - Remove intake hose -1-, connector -2- and hose -3- from mass air flow sensor. - Remove complete air cleaner housing by removing bolts -4- and -5-. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Ignition System/Service Precautions/Technician Safety Information Page 4741 - Tighten nuts -arrows A- to 10 Nm. - Tighten both bolts -arrows B- to 25 Nm. - Insert protective sleeve of selector lever cable in cover. - Install tunnel heat shields front and center. - Fit selector lever cable in bracket on front heat shield. - Reconnect exhaust system. - Fit selector lever cable -1- in retainer -arrow- on engine. - Loosen bolt -2- at front ball socket of selector lever cable -1-. - Place selector lever cable in support bracket/transmission and push onto lever/selector shaft -4using a pair of pliers. - Fit new circlip -3- to selector lever cable at support bracket/transmission. - Tighten bolt -2- (13 Nm). - Check selector mechanism. Page 5032 - Remove gear lever housing front securing nuts (arrows). - Separate front exhaust pipe -A-. - Remove cross support -B- below exhaust system. - Loosen heat shield -C- in forward area. - Remove heat shield -D-. - Unbolt selector housing from body. - Swing gear shift housing down and remove with selector cables. Installing Installation is carried out in the reverse sequence. Also, note the following: Selector mechanism up to 12.00 To reuse cables, cable locking mechanisms must be replaced. Page 3517 - Connect VAG1598/31 test box to control module wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring for open circuit between test box and harness connector using wiring diagram. - Terminal -1- + socket 98 - Terminal -2- + socket 86 - Terminal -3- + socket 108 Wire resistance: max. 1.5 ohms - Also, check if wires are shorted together. Specified value: infinity ohms If no malfunction is found in the wiring and voltage was present between terminals -1- + -3-: - Replace Camshaft Position (CMP) sensor - G40-. Refer item 2 under "Powertrain Management/Ignition System", See: Ignition System/Service and Repair - Check DTC memory. if necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If the DTC memory has been erased or the ECM was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. If no malfunction is found in the wiring and no voltage was present between terminals -1- + -3-: - Replace Engine Control Module (ECM). Page 4364 1. Supporting ring - 4-piece, unclip from inner plate carrier - Inserting see Fig. 2 2. Inner plate carrier - Inserting see Fig. 4 - Assembling see Fig. 2 3. Circlip - Different thicknesses - Mark after removing and insert in same position 4. Thrust plate - Smooth side faces inner plate - Insert together with inner plate carrier see Fig. 2 5. Inner plate - Installing see Fig. 2 6. Outer plate - Installing see Fig. 2 - Always 1.5 mm thick 7. Outer plate - Always 2 mm thick - Installing see Fig. 2 8. Corrugated washer 9. Circlip - Removing and installing see Fig. 1 10. Piston cap - Sealing lips are vulcanized to cap Service and Repair Steering Column Cover: Service and Repair Trim Under Steering Column, Removing And Installing Removing NOTE: Left trim - 2 - must be removed first because one of bolts - 3 - is located under trim - 2 -. - Remove two bolts - 1 -. - Unclip trim - 2 - at top. - Remove two bolts - 3 -. - Unclip trim - 4 - at top. Installing Installation is reverse of removal. Page 4954 Axle Nut: Specifications Rear 4. Self-locking 12-point nut, 175 Nm (129 ft lb) - Always replace Page 4056 - Also check wires for short circuit to each other. Specified value: Infinity Ohms If there is no malfunction in wire connections: - Replace Engine Control Module (ECM). Page 5344 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 1996 Crankshaft Gear/Sprocket: Service and Repair For further information regarding this component please refer to Engine Systems; Service and Repair. Page 2717 Engine Control Module: Service and Repair Motronic Engine Control Module (ECM) -J220-, Coding Engine Control Module (ECM), Coding NOTE: - A 5-character code must always be displayed during the control module identification. - The control module must be recorded if the vehicle relevant coding is not displayed or the control module has been replaced. Special tools and equipment VAG1551 Scan Tool (ST) with VAG1551/3 adapter cable Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and - 1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -7- to select "Code Control Module" function 07 and press -Q- button to confirm input. Indicated on display Code Control Module Enter code number XXXXX (32000) - Enter relevant code number for vehicle and press -Q- button to confirm input. Coding variants: Coding Vehicle 00031 Manual Transmission 00033 Automatic Transmission The control module identification and coding are indicated on the display, (example) 0219060186 MOTRONIC ME7.1G V06 -> Coding 00000 WSC 00000 Indicated on display when a non-authorized code number has been entered Function is unknown or -> cannot be carried out at the moment. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. NOTE: The code entered and shown on the display will not be used by the Motronic control module until the ignition has been switched off once. An incorrect coding leads to: - Engine running malfunctions (rough gear changes, load change jerks, etc.). - Increased fuel consumption. - Increased exhaust gas emissions. - Malfunctions stored in DTC memory which are not actually present. - Functions will not be performed (Oxygen Sensor (O2S) control, activation of the EVAP system, etc.). - On front wheel drive vehicles the traction control will not function (TC warning lamp comes on). Page 5143 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1703 All functions, which could previously be performed with V.A.G 1551/1552, can also be performed with the new tester VAS 5051 in the vehicle self-diagnosis operating mode: - VAS 5051 Vehicle diagnosis, testing and information system ATF Level, Checking Conditions for performing check Transmission not in emergency running mode, ATF temperature not above approx. 30°C - Vehicle level - Selector lever at "P" - Remove sound insulation tray. - Remove sound insulation from left longitudinal member. - Secure reservoir of ATF filling system V.A.G 1924 to vehicle. - If using tester VAS 5051, connect diagnosis cable VAS 5051/1 or VAS 5051/3 with ignition switched off to Data Link Connector (DLC). Page 3270 Information Bus: Electrical Diagrams Diagram 74/2 IMPORTANT NOTE: This manufacturer uses "Track" style wiring diagrams. For information on how to use these diagrams effectively, please refer to Diagram Information Instructions. See: Diagrams/Diagram Information and Instructions Page 5636 Load Compensator: Adjustments Adjusting brake pressure regulator Rear axle test pressure too high: ^ Release tension on regulator spring. Rear axle test pressures too low: ^ Increase tension regulator spring. Note: Do not adjust with brake pedal depressed. Use the following work sequence: ^ Read pressure. ^ Release brake pedal. ^ Adjust spring. ^ Depress brake pedal again. ^ Read pressure and if necessary, readjust. ^ Remove pressure gauges and bleed brake system. Page 2859 - Additionally, check wires all for short to one another. Specified value: infinity ohms If no wiring fault is detected: - Replace Heated Oxygen Sensor (HO2S) -G39- before Three Way Catalytic Converter (TWC), item 30. Refer under "Fuel Delivery and Air Induction/Fuel Injector", See: Fuel Delivery and Air Induction/Service and Repair - Check DTC memory, if necessary, repair any malfunctions and then erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Heater Check Heated Oxygen Sensor (HO2S) -G39- Before Three Way Catalytic Converter (TWC), Checking NOTE: Only gold plated terminals may be used to repair the contacts in the oxygen sensor harness connectors. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG 1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test requirements - Fuse 43 OK - Battery (B+) voltage at least 11.5 V - Fuel pump relay OK Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. When doing this engine must be running at idle. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08. Indicated on display Read Measuring Value Block Input display group number XXX Page 5485 ^ Press brake pedal in direction of brake booster and hold. 1 Brake pedal 2 Push rod 3 Retaining tabs ^ Insert special tool T 10006 and pull in direction of driver's seat while counter-holding on brake pedal -1-. Notes: ^ Do not allow the brake pedal to move backward when pulling on special tool T10006. ^ The special tool presses the push rod head off the retaining tabs. ^ The illustration shows the pedal cluster removed. ^ Pull special tool T 10006 and brake pedal towards driver's seat. Note: The brake pedal will now be pulled off the push rod ball head. Connecting ^ Hold push rod ball head in front of mounting and push brake pedal in direction of brake booster. Push rod ball must be heard to snap into place Continue installation in reverse order of removal. ^ Adjust brake light switch Front Brakes Brake Pad: Service and Repair Front Brakes FS III Brake Caliper, Servicing Brake pads, removing and installing Special tools and equipment required ^ VAG 1331 Torque wrench or equivalent ^ Piston resetting tool Removing ^ Remove protective caps. ^ Remove both guide pins (arrows) from brake caliper. ^ Remove brake caliper housing and secure with wire so that weight of caliper does not stress or damage brake hose. ^ Remove brake pads from brake caliper housing or from brake carrier. Installing Note: Before inserting new brake pads, press the piston back into the cylinder with the piston resetting tool. Before pressing the piston back, draw off brake fluid from the reservoir with a bleeder bottle. Otherwise, particularly if the brake fluid reservoir has been topped up, fluid will overflow and cause damage. Fuse Holder, Removing and Installing Fuse Block: Service and Repair Fuse Holder, Removing and Installing Fuse Holder And Relay Carrier CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off. - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. Fuse Holder, Removing And Installing - Carefully pry-off side cover from instrument panel (left). - Remove driver's side instrument panel trim. - Remove screws -B- (2 Nm) and then press locking device -C- when doing this pull fuse holder -Aout inward. Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 1825 Page 2935 Air Flow Meter/Sensor: Testing and Inspection With Generic Scan Tool Mass Air Flow (MAF) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of Mass Air Flow (MAF) sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Mass Air Flow (MAF) Sensor -G70- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check: - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values Function test - Connect diagnostic tester. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Start engine and let run at idle. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 16: Air flow quantity at Mass Air Flow (MAF) sensor". - Check specified value of air flow quantity at Mass Air Flow (MAF) Sensor at idle. Specified value: 3.00 to 5.00 g/sec - End diagnosis and switch ignition off. If specified value is obtained, but DTC memory has a DTC concerning Mass Air Flow (MAF) sensor: - Check voltage supply of Mass Air Flow (MAF) sensor. If specified value is not obtained: - Check signal and Ground (GND) wires of Mass Air Flow (MAF) sensor. Voltage supply for Mass Air Flow (MAF) sensor, checking Specifications Compression Check: Specifications Compression pressure New 10 - 13 bar Max. wear 7.5 bar Permissible variation between cylinders 3 bar Page 6122 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4417 1 - To Pin 63 of TCM connector 2 - To Pin 40 of TCM connector 3 - To pin Pin 1 of TCM connector (Ground) 4 - Vacant 5 - To Pin 18 of TCM connector 6 - To Pin 62 of TCM connector 7 - To Pin 23 of TCM connector (voltage supply terminal 15) Checking supply voltage. - Connect test box VAG 1598/18. - Switch multimeter to 20 V measuring range. - Switch ignition on. - Measure between terminal 7 and terminal 3 (Ground) on connector disconnected from multi-function TR switch. Specification: Battery voltage - Measure from terminal 7 of connector to socket 1 on 1598/18 (Ground). - Measure from socket 23 (terminal 15) on 1598/18 to socket 1 on 1598/18 (Ground). Specification: Battery voltage If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Switch ignition off. - Disconnect Park/Neutral Position (PNP) Relay - J226-. - Set multimeter to 200 Ohms measuring range Check the wiring between the multi-pin connector on the TCM and the connector on the multi-function TR switch. - Measure between sockets 1 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 18 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 18 on VAG 1598/18 and terminal 5 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 63 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 63 on VAG 1598/18 and terminal 1 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. Engine Controls - Silicone Sealer/Lubricant Precautions Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - Silicone Sealer/Lubricant Precautions 00 08 04 Aug. 18, 2008 2002412 Supersedes T.B. Group 00 number 07 01 dated Jan. 19, 2007 due to removal of Routan applicability. Vehicle Information Condition Sealants, Liquid Gaskets and Lubricants Containing Silicone Technical Background Damage to Mass Air Flow (MAF) sensors and Oxygen sensors may result from use of sealants, liquid gaskets, or lubricants containing silicone. Production Solution N/A Service Many detailing products contain silicone. If vehicle engine is running when spraying products which contain silicone (tire dressing, exterior and interior trim cleaner / protectants), silicone may be drawn into the intake system and can contaminate the MAF sensor and/or oxygen sensors. ^ Do not use sprays containing silicone on or near running engines with a Mass Air Flow sensor or Oxygen sensors. In addition, if using sealants or liquid gaskets containing silicone on or near the engine of a vehicle with a MAF sensor or oxygen sensors: ^ Always allow the silicone to cure properly before starting and running the vehicle's engine. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3299 Diagnostic Trouble Code (DTC) Memory, Checking (function 02) NOTE: DTCs stored in memory along with corresponding malfunction descriptions can only be displayed by initiating the On Board Diagnostic program and checking DTC memory (function 02). - Connect VAG 1551 Scan Tool, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 19, "Gateway". - Press -Q- button to confirm input. - Press -> button until "Select function" appears in display. - Switch on printer with the PRINT button (indicator lamp in button lights up). Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -2- to select "Check DTC memory" function 02. Indicated on display: Rapid data transfer Q 02 - Check DTC memory - Press -Q- button to confirm input. The number of stored DTCs appears in the display. X DTC's recognized! Stored DTCs are displayed and printed out one after another. - Check print-out against DTC table and repair all malfunctions as necessary. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/VAG Code Charts/CAN Bus If "No DTC recognized" is displayed the program will return to the initial position after pressing -> button. No DTC recognized! Indicated on display: Rapid data transfer HELP Select function XX If something else is displayed: - See: Scan Tool Testing and Procedures/End Output (Function 06) - Switch ignition off - Disconnect VAG 1551 from Data Link Connector (DLC). Without Manufacturer Scan Tool The manufacturer does not provide a procedure for reading diagnostic trouble codes without a scan tool. Diagnostic Trouble Code (DTC) Memory, Erasing (Function 05) Diagnostic Trouble Code (DTC) Memory, Erasing (function 05) NOTE: After DTC memory is erased, its contents are automatically output. If DTC memory cannot be erased, check DTC memory again and repair malfunction. Prerequisites - DTC memory checked. See: Reading and Clearing Diagnostic Trouble Codes/Diagnostic Trouble Code (DTC) Memory, Checking (Function 02)/With Manufacturer Scan Tool - All malfunctions repaired. After successful DTC memory check: Indicated on display: Page 430 Part 1 Page 6555 Air Duct: Service and Repair Defroster Duct, Installation Position Defroster duct, installation position - Attach defroster duct -2- to heater unit. - At the same time position defroster duct -2- in instrument panel cross member -1-. Page 4225 Transmission Position Switch/Sensor: Service and Repair 4 Speed Automatic 01M Remove & Install Multi-Function TR Switch Multi-Function Transmission Range (TR) Switch -F125Removing and installing -F125- Switch ignition off - Disconnect connector from multi-function TR switch. - Remove bolt and retainer. - Remove multi-function TR switch. - Replace seal. Installation is performed in the reverse order. - Tighten bolt to 10 Nm (7 ft lb). Relay Positions Compiled from every wiring section 1998-2004 Relay Box: Application and ID Relay Positions Compiled from every wiring section 1998-2004 RELAY LOCATIONS Relay Panel & Thirteenfold Auxiliary Relay Panel Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 - Auxiliary Emergency Flasher Relay (404) 2 - Relay for Motor Remote Unlock Rear Lid (79) 3 - Starting Interlock Relay (53) (185) (465) 4 - Fog Light Relay (53) 5 - Control Module for Multi-function Steering Wheel (450) 6 - Control Module for Multi-function Steering Wheel (450) 7 - Daytime Running Lights Change-over Relay (173), from April 1999 8 - Daytime Running Lights Change-over Relay (173), through March 1999 9 - Dual Horn Auxiliary Relay (53) 10 - Glow Plug Relay (180) 10 - Warning Lamp Auxiliary Relay (200) 11 - Park/Neutral Position (PNP) Relay (175) 12 - Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 - Dual Horn Relay (53) 2 - Load Reduction Relay (18) (100) 4 - Fuel Pump (FP) Relay (409) V - Wiper/Washer Intermittent Relay (192) (377) (389) VI - Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing. Page 1708 Fluid - A/T: Testing and Inspection 5 Speed 09A Transmission ATF, checking level and topping up Special tools and equipment - V.A.G 1306 Drip tray - V.A.G 1551 Scan Tool - V.A.G 1551/3 Cable - V.A.G 1924 Reservoir - V.A.G 1331 Torque wrench - VAS 5051 Vehicle diagnosis, testing and information system - Diagnosis cable VAS 5051/3 If ATF needs to be topped up, then only ATF with Part No. 052 990 A2 may be used Page 4439 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 2110 Lo-NI Page 6497 Pulling bearing inner race out of hub Removing circlip Pressing wheel bearing out of wheel bearing housing Greasing hole with Molikote grease completely Molykote grease, G 052 723 A2 Page 4067 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Page 3555 - Measure sensor resistance between terminals 2 + 3 at connector to sensor. Specified value: 480...1000 Ohm - Check sensor for shorts between terminals 1 + 2 and 1 + 3. Specified value: infinite Ohm If specified values are not obtained: - Replace Engine Speed (RPM) Sensor -G28-: Vehicles with engine code AFP, item 25, - Vehicles with engine code BDF, item 16. - Check wires between test box and 3-pin connector for open circuit according to wiring diagram. Terminal 1 + socket 108 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no DTC is found on sensor: - Connect test box to control module wiring harness connect test box for wiring test. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Terminal 2 + socket 90 Terminal 3 + socket 82 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wires: - Remove sensor and check sensor wheel for secure fit, damage, and run-out. NOTE: There is a larger-sized gap on the sensor wheel. This gap is the reference mark and does not mean that the sensor wheel is damaged. If nothing seems to be wrong with the sensor wheel: - Replace Motronic Engine Control Module (ECM) -J220-. Page 2098 using the VAS 5051 The results and diagnostic log must be sent to the Volkswagen Technical Assistance Center (TACS) before any repairs are performed. 4. Advise the customer that if the low oil level warning light comes on before the 630 mile (1014 km) test is completed, the vehicle must be taken directly to the Dealership for part # 2 of the oil consumption test, regardless of the miles accumulated. The customer should not add any oil. Note: Page 66 - Antenna cables - Touareg 2004 > 2006 Tip: Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information. Lock Cylinder, Removing and Installing Ignition Switch Lock Cylinder: Service and Repair Lock Cylinder, Removing and Installing Ignition/starter Switch and Lock Cylinder, Removing And Installing Lock Cylinder, Removing And Installing CAUTION! - Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch off all electrical consumers. - Switch the ignition off and remove the ignition key. - Disconnect negative (-) battery terminal. - When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks Removing - Disconnect battery. - Remove steering column switches. - Where applicable, carefully disconnect electrical connection for the induction coil for anti-theft immobilizer from lock cylinder. NOTE: - If equipped, the induction coil for anti-theft immobilizer is integrated with the lock cylinder and cannot be serviced separately. - Insert ignition key in lock cylinder and turn to position "Drive". Position of key in lock cylinder: 1 - Position "Stop" 2 - Position "Drive" 3 - Position "Start" Page 4422 Control Module: Service and Repair 5 Speed Automatic 09A Removing control module - Switch ignition off, open hood. - Remove wiper arms and cowl panel: - Release multi-pin connector, then disconnect connector from control module. - Remove screws -arrows-. - Remove control module. Installing control module Installation is performed in the reverse order of removal. - Locate multi-pin connector on control module -J217- pins (arrows) then lock multi-pin connector. Capacity Specifications Final Drive Fluid: Capacity Specifications 4 Speed 01M Planetary gearbox fluid Capacity ............................................................................................................................................... ............................ 5.3L (filled for life, no change) Type ....................................................................... .............................................................................................................................................. VW ATF VW Part no. ......................................................................................................................................... ........................................ G 052 162 A1 (0.5 liter) VW Part no. .......................................................... ....................................................................................................................... G 052 162 A2 (1.0 liter) Final drive Initial filling ........................................................................................................................................... .................................................................... 0.75L Oil change ............................................................ .................................................................................................................... Filled for life (no change) Type ..................................................................................................................................................... .................. Gear oil SAE 75W-90 (synthetic oil) VW Part no. ............................................................. .................................................................................................................... G 052 145 A1 (0.5 liter) VW Part no. ......................................................................................................................................... ........................................ G 052 145 A2 (1.0 liter) 5 Speed 09A Planetary gearbox & final drive Capacity ............................................................................................................................................... ................................................... 7.0L (filled for life) Type ..................................................................................................................................................... ........................................................................... ATF VW Part no. ......................................................................................................................................... ............................................................ G 052 990 A2 Page 2957 - Switch ignition off. If there is no voltage: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Check for open circuits in wires between test box and connector according to wiring diagram. Terminal 1 + socket 98 Terminal 2 + socket 86 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in the wires and there was voltage between terminals 1 + 3: - Replace Camshaft Position (CMP) Sensor -G40-, item2. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are found in wires and there was no voltage between terminals 1 + 3: - Replace Engine Control Module (ECM). Test sequence (Vehicles with engine code BDF) - Disconnect 3-pin connectors from Camshaft Position (CMP) sensors: 1 - Camshaft Position (CMP) Sensor -G40- intake camshaft 2 - Camshaft Position (CMP) Sensor 2 -G163- exhaust camshaft NOTE: Before disconnecting harness connectors, mark allocation to component. A/C Pressure Switch F129 A/C Pressure Sensor/Switch - Cooling Fan: Locations A/C Pressure Switch F129 F129 A/C Pressure Switch - engine compartment, right rear Page 4161 Control Module: Locations J217 - Transmission Control Module (TCM) Page 1255 - Check status of the oxygen sensor control before Three Way Catalytic Converter (TWC) (display field 1). Display Group 030 Explanation of 3 digit number block in display field 1 Page 1300 Part 2 Page 5697 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit With Manufacturer's Scan Tool Clutch Switch: Testing and Inspection With Manufacturer's Scan Tool Clutch Pedal Switch (Clutch Vacuum Vent Valve Switch -F36-) Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -6- and -6- to input display group number 66 (066) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 06 -> 1234 - Observe display in display field 2 (2nd digit from left). Specified value: x 0 x x - Depress clutch pedal fully and observe display in display field 2. Specified value: x 1 x x - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 4507 - Test-drive vehicle and inspect transmission for signs of leakage. Page 4320 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch Transmission Position Switch/Sensor: Service and Repair 5 Speed Automatic 09A Remove/Install/Adj. Multi-Function Switch 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Page 3581 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) Page 4575 Test table Page 239 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 951 Outside Temperature Display Sensor: Locations Outside Air Temperature Sensor (Vehicles With Climatronic Control Module) G17 - Outside Air Temperature Sensor (Vehicles with Climatronic Control Module) Page 2141 ^ Indicator lamp for oil pressure (K3) must illuminate for approximately 3 seconds after the ignition is turned on. ^ Oil temperature at least 80°C Oil pressure switch, checking - Remove the 1.4 bar oil pressure switch (F1) (black insulation) and screw it into the tester. - Screw the tester into the oil filter housing in place of the oil pressure switch. - Ground the tester brown lead H. - Connect the V.A.G 1527 B diode test lamp to the battery positive terminal (+) and to the oil pressure switch using the auxiliary cables from V.A.G 1594 A. The Light-Emitting Diode (LED) should not illuminate. If the LED illuminates: Replace the 1.4 bar oil pressure switch (F1). If the LED does not illuminate: Let the engine continue to idle. The light-emitting diode should light at 1.2-1.6 bar. Otherwise, replace the 1.4 bar oil pressure switch (F1). Oil pressure, checking Test condition ^ The VAG 1342 oil pressure test instrument is riot connected ^ Oil temperature at least 80°C Test sequence Start the engine and let it idle. Specification: oil pressure: at least 2.0 bar - Increase engine speed. ^ The oil should be at least 2.0 bar at 2000 rpm and 80°C oil temperature. ^ The oil pressure may not exceed 7.0 bar - Replace oil pump if necessary. Page 1689 - Indicated on display: ‹› Press buttons -0- and -8-. (Function "Read measured value block" is selected with -08-). - Indicated on display: ‹› Confirm entry with Q button. - Indicated on display: ‹› Press buttons-0--0--5-. (-005- selects the "Display group number -005-"). ‹› Confirm entry with 0 button. - Indicated on display: ‹› First display zone shows ATF temperature. - Bring ATF to test temperature. ‹› Test temperature: 35° C to 45 °C (95 to 113° F). - Remove ATF level plug from oil pan. - ATF in overflow line runs out. - If ATF drips out of hole: ‹› ATF need not be topped up. - Install new seal (arrow 1) on plug and tighten to 15 Nm (11 ft.lb). ATF check is completed. - Plug (arrow 3) and cap (arrow 4) remain closed. Page 4647 - Install multi-function TR switch -F125- on selector shaft. Installation position: The groove -1- in the selector shaft must align with the multi-function TR switch -F125- marking -2-. - Screw in multi-function TR switch -F125securing bolts (arrows) hand tight. - Place adjusting device on selector shaft and secure. - Shift lever/selector shaft on transmission to position "N". - Turn switch until hole on switch housing -1- aligns with hole of adjusting device. - Insert pin -2- from adjusting device. - Tighten multi-function TR switch -F125- securing bolts (arrows) to 6 Nm. Further installation in reverse order Check selector lever cable adjustment, Refer to Transmission and Drivetrain. - Enter radio code. Puller - AST Tool # T 40001 Camshaft Gear/Sprocket: Tools and Equipment Puller - AST Tool # T 40001 Puller AST tool# T 40001 Puller used to remove cam sprockets. Comparable to VW # 3032. Applicable: VW 4 cylinder TDI, VW/Audi V6(5V) and Audi V8 (40V). Includes 17mm and 23mm pulling arms. (For 2.0L 4V Direct Injection Engine (BPY)(BPG)(BWT), order additional arms; T 40001-6 and T 40001-7, available separately.) - Used to Remove Cam Sprockets - Comparable to VW # 3032 - Includes 17mm and 23mm pulling arms Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Additional Tools Possibly Required: Page 2348 - Fill with coolant up to upper mark on cross hatched area on coolant recovery bottle. - Close coolant recovery bottle. - Expose heater controls and turn-off air conditioning if necessary. - Start engine and run at approximately 2000 rpm for about 3 minutes. - Keep engine running until fan starts. - Check coolant level and fill as necessary. The coolant level must be within the cross-hatched region when the engine is running warm. It must be above the lower mark if the motor is cold. Testing and Inspection Load Compensator: Testing and Inspection Brake pressure regulator, checking and adjusting Special tools and equipment required ^ VAG 1310 Brake pressure gauge The brake pressure regulator is mounted on a bracket and mounted to the rear axle. The regulator is controlled from the rear axle by a spring. Checking function ^ Depress brake pedal firmly once and release quickly (vehicle standing on its wheels). Brake pressure regulator must move. Checking and adjusting Requirements ^ Vehicle emptied of all cargo and passengers ^ Driver (approximately 75 kg [165 lbs.]) in driver's seat ^ Full fuel tank ^ Full windshield washer / headlight washer reservoir ^ Spare tire, tool kit and jack in place Checking ^ Lift vehicle and connect pressure gauges to left front and right rear brake calipers. ^ Bleed both gauges. ^ Lower and bounce rear of vehicle several times. ^ Depress brake pedal to obtain specified pressure at front axle, then read pressure at rear axle. ^ Compare reading with specifications and if necessary adjust. Specifications for load dependent brake pressure regulator Rear disc brakes Front axle 70 bar (1015 psi) Front axle 100 bar (1450 psi) Rear axle 36 - 42 bar (522 - 609 psi) Rear axle 49 - 55 bar (710 - 798 psi) Page 952 Outside Temperature Display Sensor: Locations Outside Air Temperature Sensor (Vehicles W/Out Multi-Function Indicator MFI) G17 - Outside Air Temperature Sensor (vehicles w/out Multi-Function Indicator MFI) Page 5933 ^ Reprogram remote using VAS 5051/5052. ^ If remote remains inoperative and all diagnostic avenues have been exhausted, replace remote. Key Points to Remember ^ DO NOT attempt to reuse original battery regardless of voltage reading. A new battery must be installed. ^ DO NOT attempt to separate key portion from remote on a Touareg or Phaeton. There is a removable cover to access battery. ^ Pressing down on any button of the remote for 5 seconds, before installing the replacement battery (capacitive discharge), will erase the battery memory of the remote. If this is not done, remote will be inoperative. ^ There is no need to program remote if battery is removed for testing or replacement. However, if another problem exists, proper diagnosis needs to take place before remote is replaced. Warranty Warranty Test Center Notes: ^ 100% of remote replacements will be requested by Warranty Test Center for testing. ^ Synchronization is not considered a warrantable condition. ^ Claims that involve remote programming may be debited without proper documentation in the warranty claim. ^ Replacement battery must be included with replaced remote. ^ Any remote a technician has replaced without first performing this technical bulletin will be automatically subject to a debit. ^ Any remote that has failed due to water contamination is not considered warrantable. ^ All remotes that test NTF by Warranty Test Center may be debited. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 5545 Warranty Page 5615 <-- Place electrical connector -1- into ABS control module and push in direction of -arrow 2- <-- Lock electrical connector to ABS control module by pushing latch down -arrow 3^ If applicable, reinstall secondary air relay box and reinsert harness in support clip ^ If applicable, reconnect electrical connector to brake fluid reservoir <-- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.) <-- If applicable reconnect air hose -4- from secondary air pump to air filter box -5<-- Reconnect vacuum line -7- to air box (TDI vehicles only) <-- Reconnect air intake hose to mass air flow sensor and secure with clamp -3<-- Reconnect electrical connector -1- to mass air flow sensor -2^ Reconnect the ground cable (GDN) from the negative (-) battery terminal ^ In the vehicle, remove brake pedal depressor from the brake pedal ^ Proceed to Section D Section D Section D - Code ABS Control Module ^ Connect VAS 5051 to data link connector located under dash left of steering column Page 3297 Indicated on display: Rapid data transfer HELP Select function XX - After the HELP button is pressed, a list of the possible functions is printed out. List of available functions Page 2987 Fuel Pressure: Specifications Residual Pressure After 10 minutes there must be a residual pressure of at least ................................................................................................................................ 2.0 bar. Page 728 Hood Sensor/Switch (For Alarm): Locations Hood Alarm Switch F120 - Hood alarm switch Page 6093 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 608 Tip: Part number(s) are for reference only. Always see ETKA for the latest part(s) information. Locations Cruise Control Module: Locations J453 - Control Module For Multi-Function Steering Wheel - in 13 position relay carrier, behind driver's side lower footwell cover positions 5 and 6 Page 2112 Pr-Sh Page 3059 Display Group 4 Continuation of check when display = ambient temperature - Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module. - Note intake air temperature value in display field 4. - Spray sensor (arrow) with commercial chilling agent while observing temperature value. Temperature value must decrease. - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation of check when display reads approx. -40.0 °C: Locations Memory Positioning Module: Locations J136 - Memory seat control module Page 6077 Relay Box: Application and ID Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 5467 ^ Using extractor tool from wiring harness repair set VAS 1978, push out applicable terminals. ^ Disconnect wheel speed sensor wiring connector. ^ Replace faulty wheel speed sensor wiring. ^ Connect speed sensor to speed sensor wiring. ^ Secure speed sensor wiring (arrows). Note: Make sure the wiring is not twisted in the wheel well. ^ Install pin connectors in connector housing. ^ Using installation tool from VAS 1978, push individual wire seals to stop. ^ Secure terminals by engaging purple latch and install cover of multi-pin connector. Page 1057 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams EPC Warning Lamp Page 5381 CAUTION: - BRAKE FLUID IS POISONOUS. - BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. - CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. - Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper - With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw - Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle - Ensure that brake fluid in the reservoir is at the correct level - Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 2744 Edna St., Windsor ON N8Y 1V2, CANADA ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL. Page 2347 - Also pull coolant hose out from oil cooler -arrow- to drain coolant from engine. Note: Please follow regulations for disposal! Refilling Notes: To satisfy TL VW 774 D, only G 12 may be used as a coolant additive. Color coding: red. - Never mix G 12 with any other coolant additives! - If the liquid in the coolant recovery bottle is brown, this means that G 12 was mixed with another coolant and the coolant has to be changed. - G 12 and additives which are labeled "satisfies TL VW 774 D" prevent damage from freezing and corrosion and prevent lime deposits. They also raise the boiling point For these reasons, the cooling system must be filled with antifreeze and anti-corrosion agents throughout the year. - The coolant's higher boiling point will contribute to operational reliability under higher engine loads, especially in tropical climates. - The antifreeze protection must go down to - 25° C (in Arctic climates down to -35°a C). - The concentration of the coolant may not be reduced by topping up during the warm seasons or in warm countries. The proportion of additive must be at least 40%. - If the climate requires stronger antifreeze protection, the portion of G 12 can be increased, but never above 60% (antifreeze protection down to about -40° C), otherwise the antifreeze protection will begin to decrease again and the cooling effect will be reduced. - Do not reuse the same coolant if the radiator, heat exchanger, cylinder head or cylinder head gasket have been replaced. Recommended mixing ratios 1) The amount of coolant may vary depending on the vehicle accessories. - Tighten drain plug into radiator return. - Push coolant hose onto oil cooler connection and pull it tight. Page 2715 - Switch ignition off. NOTE: If the basic setting of the control module is interrupted, the cause could be one of the following: - Throttle valve cannot reach the mechanical stop because of contamination (e.g. oil deposits or an incorrectly adjusted accelerator pedal cable). - Battery voltage too low. - Throttle valve control module or wiring is faulty. Refer to "Throttle Valve Control Module, Checking", See: Electronic Throttle Control Module/Testing and Inspection After an interruption the fault "17973" is stored in DTC memory. When the ignition is switched on again, the basic setting is automatically performed again. - End basic setting by pressing -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 3970 - Observe the flange fitting position. The marks on the flange must coincide with the marks on the fuel tank -arrows-. - Perform basic settings. - Read readiness code: - If fault memory was erased or engine control module was disconnected from positive voltage supply, readiness code must be regenerated: Page 5728 Owner Letter Work Procedure Work Procedure Overview: This procedure will describe checking the ABS control module part number and supplier code and removing and installing the ABS Control module Special Tools: - Diagnostic tool - V.A.G. 1551 or VAS 5051 - Brake pedal loading device - V.A.G. 1869/2 or equivalent - Brake bleeding tool - VAS 5234 or US 1116 Page 3687 - Press the keys "0", "6" and "2" for "display group number 62" and acknowledge the entry by pressing "Q". Indicated on display (1 - 4 display fields) Check the specification of sensor 1 (G79) from the message in field 3, while engine is idling. Specification: 12-97 % - Check the specification of sensor 2 (G 185) infield 4, while the engine is idling. Specification: 4-49% Note: The engine control unit converts the voltage of the angle transmitter in percent, based on 5 volts, and displays it (5 volts represents 100 %). - Slowly actuate the accelerator until full throttle and simultaneously observe the percentages displayed in fields 3 and 4: ^ The percentage in field 3 should increase steadily. Here, the range of tolerances 12-97 % is not totally utilized. ^ The percentage in field 4 should increase steadily. Here, the range of tolerances 4-49 % is not totally utilized. Note: The value displayed in field 3 should always be about twice as large as the value in field 4. If the displays do not behave as described: Check the power supply and the electrical connections of the throttle position sensors Refer to Powertrain Management. Checking the power supply and cables to the control unit - Remove the driver side shelf: Refer to Body and Frame. - Disconnect the 6 pin connector for the throttle position sensor. - Turn on the ignition. - To measure the voltage, connect the multimeter to the following contacts of the connector: ^ Contact 1 + ground ^ Contact 1 + 5 ^ Contact 2 + ground ^ Contact 2 + 3 ^ Specification: at least 4.5 V - Turn off the ignition. If the specifications are not achieved: - Connect the V.A.G 1598/31 test box to the control unit wiring. Do not connect the engine control unit. Service and Repair Fuel Distance/Mileage Module: Service and Repair Adaptation (function 10) Use this function to initiate and store the following changes: - Adaptation of odometer reading when replacing/exchanging instrument cluster. - Adaptation of fuel gauge reading. - Adaptation of Multi-function Indicator (MFA) fuel consumption indicator (where applicable). Individual functions are called up using the appropriate channel number from adaptation table. Adaptation table: Multi-function Indicator (MFI) Fuel Consumption Indicator, Adaptation NOTE: - Consumption indicator can only be adapted once between 85% and 115%. - Value must be entered in steps of 5%. - Connect scan tool VAG 1551, select operating mode 1 "Rapid data transfer", switch on ignition and enter address word 17 "instrument cluster". - Press -Q- button to confirm input. Page 5845 Battery: Vehicle Damage Warnings Handling Instructions CAUTION! Before beginning repairs on the electrical system: - Obtain the anti-theft radio security code. - Switch the ignition off - Disconnect the battery Ground (GND) strap. - After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows. NOTE: - Battery posts and terminals must no longer be greased. - In order to prevent damage to the battery housing, battery terminals must be placed on battery posts without using force (by hand only). - Battery post/terminal nut -arrow- tightening torque: 6 Nm (53 in lb) - Additional battery post/terminals, tightening torque: 6 Nm (53 in lb). Page 4474 Fill Plug: Specifications 5 Speed 09A Transmission 5 Speed 09A Transmission Level Plug (with Overflow Line Tube)................................................................................................... ................................................................. 15 Nm Fill Plug (with protective cap) Note: Always replace cap. The cap secures the sealing plug. Page 65 - Antenna cables - New Beetle with Satellite radio (convertible) - Antenna cables - W8 Passat Page 1302 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 4642 Part 2 Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Locations Shift Interlock Solenoid: Locations N110 - Shift lock solenoid Page 183 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Specifications Brake Fluid: Specifications Brake Fluid Type Use only brake fluid that meets SAE specifications J 1703 and conforms to Federal Motor Vehicle Standards 116. DOT 4 Page 2377 ^ Seal engine harness grommet in engine compartment (where overlay harness was pulled through) with Butyl sealer. Engine overlay harness, routing to coolant bottle ^ Engine overlay harness must be routed following factory harness behind fuel and evaporative emission tubes and into plastic clip (arrow) that secures factory harness. ^ Continue overlay harness routing along original harness back to coolant reservoir. ^ Install new coolant reservoir. ^ Cut old coolant reservoir connector from original harness, fold and tape wires back to harness using vinyl tape (see above - Unused wiring, taping back to harness). ^ Connect overlay harness connector to new coolant reservoir. ^ Locate connector to washer level sensor and cut from factory harness (tape brown/white wire back to harness (see above - Unused wiring, taping back to harness). ^ Splice purple/white wire from overlay harness to factory harness using yellow splice (seal using hot air blower). Vehicles with Climatronic ^ Disconnect and inspect ambient temperature sensor -G17- connector for coolant contamination (located behind bumper left side). If coolant contamination is NOT found: ^ Cut brown/white wire from ambient temperature sensor harness approx. 5 cm (2 in.) away from connector. Using light yellow splice connectors Part No: 111971941A: ^ Adding wire as necessary to reach sensor, splice brown/white wire from overlay harness to ambient sensor connector wire (follow and tape to existing harness as necessary) (use Part No: 000979981 for additional wire). If coolant contamination is found: ^ Install new ambient temperature sensor. Page 5166 Page 3866 - Check wires between test box and 5-pin connector for open circuit according to wiring diagram. Terminal 3 + socket 27 Terminal 4 + socket 53 Terminal 5 + socket 29 Wire resistance: max: 1.5 Ohm - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no DTCs are found in wires: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4 , - Vehicles with engine code BDF, item 6 . - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Page 120 - Remove B-pillar lower trim to remove 5 - Door control module, RR For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 6 - Door lock, RR Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 7 - Motor for fuel tank lid unlock -V155- remote release Installation position: Under C-pillar trim - To remove, remove trim up to wheel house - Remove with special socket insert T 10010 8 - Rear lid lock Bolted to rear lid - Removing: Remove trim from rear lid. - Remove lock. 9 - Rear lid actuator Bolted to rear lid - Remove with special socket insert T 10010 10 - Door lock, RL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 11 - Coupling station - Installation position: rear roof area, covered by roof trim - Remove roof trim to remove. 12 - Anti-theft alarm horn Installation position: In area of C-pillar covered by trim 13 - Door control module, RL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 14 - Coupling station Installation position: B-pillar - Remove B-pillar lower trim to remove 15 - Door lock, FL Door lock is secured to assembly carrier - Electric central locking is integrated into door lock module - Removing: Remove door trim. - Remove door lock. 16 - Controls Installed in door trim - Remove door trim to remove 17 - Door control module, FL For comfort system only - Integrated into window motor - Removing: Remove door trim. - Remove window motor. 18 - Antenna - for radio frequency remote control Under left A-pillar trim - Remove A-pillar trim to remove. 19 - Coupling station Installation position: Lower A-pillar, cove red by trim in footwell - Remove left A-pillar lower trim to remove Page 6118 Wiring Diagram Layout 1 - Track Numbers Imaginary grid lines extending from the numbers on the bottom of the diagram toward the top of the diagram. These imaginary grid lines are used for identifying wire/circuit locations on diagrams. 2 - Reference of wire/circuit continuation to another diagram Page 4700 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 1224 Knock Sensor (KS) 1 -G61- - Disconnect 3-pin harness connector at right cylinder head for knock sensor 1 (arrow). - Measure resistance between terminals 1 + 2, 1 + 3, and 2 + 3 at harness connector for Knock Sensor (KS) 1 -G61-. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Disconnect 2-pin harness connector from knock sensor 2 (arrow, at intake manifold side of cylinder block) With Manufacturer's Scan Tool Clutch Switch: Testing and Inspection With Manufacturer's Scan Tool Clutch Pedal Switch (Clutch Vacuum Vent Valve Switch -F36-) Signal, Checking Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Check conditions - Fuses 5, 10 and 29 OK - Battery voltage at least 11.5 V Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -8- to select "Read Measuring Value Block" function 08 and press -Qbutton to confirm input. Indicated on display Read Measuring Value Block Input display group number XXX - Press buttons -0-, -6- and -6- to input display group number 66 (066) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 06 -> 1234 - Observe display in display field 2 (2nd digit from left). Specified value: x 0 x x - Depress clutch pedal fully and observe display in display field 2. Specified value: x 1 x x - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 2822 - Now measure resistance between terminals 1 + 2 at connector for knock Sensor (KS) 2 -G66-. Specified value: Infinity Ohms - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Knock Sensor (KS) 1 -G61- Check wires between test box and 3-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 106 Terminal 2 + socket 99 Terminal 3 + socket 108 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms Knock Sensor (KS) 2 -G66- Now check wires between test box and 2-pin connector for open circuits according to wiring diagram. Terminal 2 + socket 107 Terminal 2 + socket 99 Wire resistance: max: 1.5 Ohms - Also check wires for short circuit to each other. Specified value: Infinity Ohms If no malfunctions are found in wires: - Replace the respective knock sensor: Knock Sensor (KS) 1 -G61-, item 7 - Knock Sensor (KS) 2 -G66-, item 17 - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data Page 297 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Reading and Clearing Diagnostic Trouble Codes Steering Wheel: Reading and Clearing Diagnostic Trouble Codes With Manufacturer Scan Tool Diagnostic Trouble Code (DTC) memory, Erasing (Function 05) NOTE: After erasing the DTC memory its contents will automatically be indicated. If the DTC memory cannot be erased, again check DTC memory and repair malfunctions. Requirements - All malfunctions repaired. - DTC memory checked. After Diagnostic Trouble Code (DTC) memory has been successfully checked: Indicated on display: Rapid data transfer HELP Select function XX - Press keys 0 and 5. (05 selects the "Erase DTC memory" function.) Indicated on display: Rapid data transfer Q 05 Erase DTC memory - Confirm entry with key Q. Indicated on display: Rapid data transfer -> DTC memory is erased The DTC memory is now erased. - Press -> key. Indicated on display: Rapid data transfer HELP Select function XX NOTE: - If this appears in the display, the test sequence is faulty. Warning! DTC memory was not checked - If this appears in the display, the test sequence is faulty. Rapid data transfer -> DTC memory was not checked - Adhere exactly to test sequence: First check DTC memory, if necessary repair malfunctions, then erase. End Output (function 06) - Press buttons -0- and -6- to select function "End output". Indicated on display: Rapid data transfer Q Page 4936 1 - Thrust bolt E-15 2 - Support E-40 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod 5 - High pressure hose with quick release coupling Pulling out wheel bearing - Remove circlip. - Install press piece - 1 - with shoulder to bearing, press sleeve - 2 - with four stepped internal diameters to wheel bearing housing, piston cylinder - 3 - with pull rod and special nut - 4 - . - Operate pump and remove the wheel bearing. 1 - Thrust tube E-5 2 - Press sleeve E-65-1 3 - Piston cylinder HKZ-15 4 - Special nut E-8-214 and pull rod Pulling off bearing inner race from hub Pressing in wheel bearing - Clean hole from wheel bearing housing With Manufacturer's Scan Tool Idle Speed: Testing and Inspection With Manufacturer's Scan Tool Idle Speed, Checking NOTE: - Idle speed, ignition timing and CO content are not adjustable. - The idle speed is regulated to specified value by the throttle position sensor in conjunction with the DIS function. - CO content regulated by Oxygen Sensor (O2S) control. Malfunctions in oxygen sensor control are detected in On Board Diagnostic (OBD) and stored as DTCs in DTC memory Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable Test requirements - Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks - All electrical consumers (e.g. lights and window defroster) must be switched off - A/C switched off - Automatic transmission selector lever in "P" or "N" position - Coolant temperature at least 85 °C See display group 004, display field 3. - Intake air temperature less than 60 °C See display group 004, display field 4. Test sequence - Connect VAG1551 (VAG1552) Scan Tool (ST). - Switch ignition on and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (when doing this engine must be running at idle). - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes - Leave VAG1551 Scan Tool (ST) connected. - Continue running engine at idle speed. Indicated on display Rapid data transfer HELP Select function XX - Press buttons -0- and -4- to select "Basic Setting" function 04 and press -Q- button to confirm input. Indicated on display Basic setting Input display group number XXX - Press buttons -0-, -0- and -1- to input display group number 1 (001) and press -Q- button to confirm input. Indicated on display: (1-4= display fields) System in basic setting 1 -> 1234 NOTE: In the "Basic Setting" function the Evaporative Emissions (EVAP) canister purge regulator valve -N80- is closed and the air conditioner compressor is switched off - Check adjustment conditions for basic setting in display field 4. Page 5993 S177 - Fuse -5- (30) in fuse bracket/battery S178 - Fuse -6- (30) In Fuse Bracket/Battery S178 - Fuse -6- (30) in fuse bracket/battery S179 - Fuse -7- (30) In Fuse Bracket/Battery General Specifications Connecting Rod: Specifications Connecting rod Axial clearance New 0.05 - 0.31 mm Max. wear 0.40 mm Radial clearance New 0.02 - 0.07 mm Max. Wear 0.10 mm Page 2475 Auxiliary radiator 1. 10 Nm 2. Retaining frame for auxiliary radiator 3. Spacer sleeve 4. Rubber disk 5. Lower bolt, 10 Nm 6. Air scoop 7. Auxiliary radiator for vehicles in hot climates 8. 5Nm 9. To Y-branch of upper coolant hose 10. To Y-branch of lower coolant hose 11. Bracket for auxiliary radiator Cooling system components, engine side Page 6397 1. Box wrench insert (commercial type, 18 mm AF) 2. Open end wrench insert (commercial type, 18 mm AF) NOTE: Check boot for damage or twisting. Tightening torque: Ball joint to control arm 20 Nm (15 ft. lbs.) + 90° Use new bolts! Ball joint to wheel bearing housing 45 Nm (33 ft. lbs.) 12-point nut for axle shaft to wheel hub 50 Nm (37 ft. lbs.) + 30° Use new nuts! Page 4347 - With selector lever in position "1" remove solenoid with locking pin and spring from the selector lever housing. Move selector lever back and forth slightly if necessary. Installing Installation is performed in the reverse order of removal. Adjust locking cable. - Check operation of ignition key withdrawal lock. - Check selector mechanism. Page 3240 Display Group 060 - Terminate engine basic setting at earliest after 30 seconds by pressing -> button. Adaptation has been performed successfully. To store the values: Page 4026 - Check wire between test box socket 121 + 2-pin connector terminal 2 for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles - Also check the wire for short circuit to B+ and Ground (GND). Specified value: infinite Ohm - Check wire between 2-pin connector terminal 1 and the Fuel Pump (FP) Relay -J17- for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm If no malfunctions are found in wires: - Replace Motronic Engine Control Module (ECM) -J220-. Page 1455 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 4421 - Locate multi-pin connector on TCM -J217- pins (arrows) then lock connector. - Perform On Board Diagnostic (OBD). - Initiating basic setting. Page 5026 - Pull gear shift boot off center console (arrow). - Pull rubber cover toward gear shift knob, if part of original equipment. Set gear lever as follows: Select neutral with gear lever. - Guide pin T10027 through hole -A- and into hole -B-. - Now turn locking mechanism on gear selector cable and gate selector cable to right onto stop (direction of arrow). The spring presses the locking mechanism into normal position. Page 5405 Use only Volkswagen approved brake fluid CAUTION! BRAKE FLUID IS POISONOUS. BRAKE FLUID MUST NOT COME INTO CONTACT WITH PAINTWORK, AS IT IS VERY CORROSIVE. CLEAN OFF ANY BRAKE FLUID SPILLAGE AS SOON AS POSSIBLE. ^ Open bleed screws in the prescribed sequence and bleed brake calipers Bleeding Sequence 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper ^ With hose still connected, leave the respective bleed screw open until brake fluid is free from air bubbles coming out of bleed screw ^ Close bleed screws and remove US 1116 or VAS 5234 brake bleeder from vehicle ^ Ensure that brake fluid in the reservoir is at the correct level ^ Test drive vehicle after bleeding brakes and create at least one ABS event to check braking system IMPORTANT: Test driving the vehicle and experiencing at least one ABS event must be done. Pump activation while stopping the vehicle must occur. Removed control units must be properly tagged with dealer number, repair order number and VIN, and returned in the box of the new unit to Volkswagen, c/o 1601 Clay St., Detroit, MI 48211 ATTENTION: (Recall - WJ) ONLY SHIP REMOVED ABS CONTROL UNITS, AS RELATED TO THIS RECALL! Page 1636 NOTE: - When installing ribbed belts that have already been used, make sure to mark the running direction when they are removed. - Before installing the ribbed belt, make sure that all subassemblies (generator, air conditioner compressor, vane pump) are tightly mounted. - When installing the belt, ensure correct seat of the ribbed belt in the belt pulleys! - Install ribbed belt. - Remove hex bolt to reapply tension to ribbed belt. - Start engine and check running of belt. - Install engine cover. - Install center and right engine compartment cover for noise insulation. Page 1562 Vehicles with front wheel drive Rear axle is not adjustable. 4. Check toe at front axle, adjust if necessary 5. Verify vehicle suspension factory code Following applies to all suspension versions Check vehicle trim height (zero position), if a measurement is out of tolerance, before adjusting = below Vehicle trim height, Zero Position If vehicle is out of specification check trim height (see illustration). Example: a vehicle equipped with an automatic transmission could stand slightly lower to one side. This is normal due to installed position of components and weight distribution. ^ Check item -a- on both left and right sides, correct if necessary. It is possible to correct trim height imbalance for front axle by adding weight to top of strut tower and/or adding weight in trunk for rear axle, example: sand bags can be used, approx. 10 kg (22 lb.) Factory codes, explanation Various suspension versions are available as optional equipment. These are identified by factory codes. Vehicle data label lists suspension version factory codes. Example of vehicle data label In this example vehicle is equipped with standard suspension 1GC (arrow). Page 3402 Page 5486 Brake Pedal Assy: Tools and Equipment Brake Push Rod Release Tool AST tool# T 10006 A Used to separate the brake servo push rod from the brake pedal. 1998 - 2008 New Beetle and more. - Made in Germany - Call AST for Pricing Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 3444 For DTC P1176 (marked with *) where the ECM software level is at the old level as shown in table, may require an ECM replacement to achieve the new software level. Warranty Information only. Required Parts and Tools No Special Parts required. No Special Tools required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 5840 Page 4663 Part 2 Page 4871 14. Master cylinder - Removing and installing. 15. Supply hose 30-3 16. Over-center spring - Removing and installing. 17. Over-center spring mounting - Install in mounting bracket - Removing and installing, to renew master cylinder 18. Stop - For clutch pedal - Installation position. 19. Self-locking hexagon nut, 25 Nm (18 ft. lbs.) - Always replace Page 1337 - Check signal and Ground (GND) wires. Testing signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and plenum chamber cover. - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. - Check wiring between test box and 5-pin harness connector for open circuit according to wiring diagram. Terminal -5- + socket 29 - Terminal -4- + socket 53 - Terminal -3- + socket 27 Wire resistance: max. 1.5 ohms - Additionally, check all wires for short circuit to one another. Specified value: infinity ohms - Check wiring additionally for short circuit to battery positive (B+)/Ground (GND). If no malfunction is found in the wiring: - Replace Mass Air Flow (MAF) sensor -G70- item 4. Refer under "Fuel Delivery and Air Induction/Air Cleaner Housing", See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Page 5237 41 - Vacant 42 - Vacant 43 - Vehicle Speed Sensor -G68- (shielding) 44 - Transmission Vehicle Speed Sensor -G38- (shielding) 45 - Supply voltage (terminal 30) 46 - Vacant 47 - Solenoid valve 4 -N9148 - Vacant 49 - Vacant 50 - Vacant 51 - Vacant 52 - Vacant 53 - Vacant 54 - Solenoid valve 2 -N8955 - Solenoid valve 1 -N8856 - Solenoid valve 5 -N9257 - Selector lever display 58 - Solenoid valve 6 -N9359 - Vacant 60 - Vacant 61 - Vacant 62 - Multi-Function TR Switch -F125- (pin 6) 63 - Multi-Function TR Switch -F125- (pin 1) 64 - Vacant 65 - Vehicle Speed Sensor -G6866 - Transmission Vehicle Speed Sensor -G3867 - Solenoid valves voltage supply 68 - Vacant Overview of test steps - Perform only those test steps recommended in the Diagnostic Trouble Code (DTC) and Measured Value Block tables - Steps listed below according to component Page 4214 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 6262 1. Power steering pump ^ Checking delivery pressure ^ Fill with oil before installing 2. Suction hose 3. Mounting bracket 4. Pressure hose 5. Hex bolt ^ 10 Nm (89 inch lbs.) 6. Clamp 7. Banjo bolt ^ 30 Nm (22 ft. lbs.) 8. Seal ^ Always replace 9. Suction hose 10. Reservoir Pressure line and suction hose (TDI and 2.0 liter engines without A/C) Page 4913 1. Self-locking 12 point nut - Tightening - Any paint residue and/or corrosion on outer Joint thread must be removed before nut is installed. 2. CV joint boot - Check for tears and chafing 3. Clamp - Tightening - Always replace 4. Multipoint socket head bolt - Always replace - M8 x 18: 20 Nm (15 ft. lbs.) +90° - M8 x28: 20 Nm (15 ft. lbs.) +90° - M10x 23: 50 Nm (37 ft. lbs.) + 45° - The initial tightening torque of the bolts M8 and M10 must be carried out in two steps. First apply a torque of 10 Nm and then the corresponding torque. 5. Triple roller joint housing 6. Triple rotor star - Chamfer (arrow) faces opposite end of axle 7. Circlip - Always replace 8. O-ring - Always replace 9. Cover - Always replace Page 1939 Variable Valve Timing Actuator: Testing and Inspection With Generic Scan Tool Valves For Camshaft Adjustment (Vehicles With Engine Code BDF), Checking Function The camshaft adjustment is load-and RPM dependent. The electrical valves for camshaft adjustment switch oil pressure onto camshaft adjusters (mechanical adjustment mechanisms), which then adjust the camshafts. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of the Valve -1- for camshaft adjustment -N205-and Camshaft Adjustment Valve 1 (exhaust) -N318- must be OK. - Fuel Pump (FP) Relay -J17- must be OK, check. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P-or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Ignition switched off. Test sequence - Disconnect 2-pin harness connector to the respective valve for camshaft adjustment: 1 - Valve -1- for camshaft adjustment -N2052 - Camshaft Adjustment Valve 1 (exhaust) -N318NOTE: Before disconnecting harness connectors, mark allocation to component. Page 1905 - Completely grease hole with Molykote grease. - Molykote grease, G 052 723 A2 - Use grease packet from repair kit - Install wheel bearing -1 - - press piece - 2 - install with collar in bearing) and piston cylinder - 3 with pull rod on wheel bearing housing. - Install thrust piece - 4 - with wide collar toward wheel bearing housing and special nut - 5 - on inside. - Press wheel bearing in by operating pump. - Insert circlip with needle nose pliers. 1 - Wheel bearing 2 - Thrust tube E-13-1 3 - Piston cylinder HKZ-15 4 - Thrust tube E-10 5 Special nut E-8-214 and pull rod Pressing in wheel hub - Install hub - 1 - and piston cylinder - 2 - with pull rod on wheel bearing. - Install special nut - 4 - and thrust piece - 3 - (with collar toward special nut) on inside. - Press in hub by operating the pump. 1 - Wheel hub 2 - Piston cylinder HKZ-15 3 - Thrust tube E-5 4 - Special nut E-8-214 and pull rod Further installation is in the reverse sequence to removal. Page 801 A/C Pressure Sensor/Switch - Cooling Fan: Locations High Pressure Sensor G65 G65 High Pressure Sensor in engine compartment, right rear, in refrigerant line Page 2699 Engine Control Module: Locations Engine Control Module Engine Control Module location The control module is located in plenum chamber. Component Locations Fuse Block: Component Locations Fuse Panel Location The fuse panel is located behind a cover on the driver side end panel of the instrument panel (dashboard). Connecting Duct, Removing Air Duct: Service and Repair Connecting Duct, Removing Connecting duct, removing 1 - Bolt 2 - Air duct connector 3 - Rear footwell duct 4 - Bracket 5 - Cover 6 - Bolt First do the following: - Remove glove box - Remove steering column cover. Removing - Remove bracket -4-. - Remove cover -5-. - Remove duct in direction of footwell -arrow -A-. Page 6261 7. Pressure hose/line ^ Check pressure ^ Fill with oil before installing Reservoir, removing and installing 1. Cap with dip stick ^ Oil level: between min. and max. marks; Engine temperature approx. 50°C (122°F) ^ Check oil level with cap screw on ^ With engine cold, oil level must not rise above Min. marking ^ Open cap with e.g. a bar ^ Arrow A: oil level with engine cold 2. Hose clamp 3. Suction hose 4. Return hose 5. Sockethead bolt ^ 10 Nm (89 inch lbs.) 6. Reservoir Pressure line and suction hose (TDI engine with A/C) Engine Controls - DTC's 00545/00638 Stored Engine Control Module: Customer Interest Engine Controls - DTC's 00545/00638 Stored Condition DTC's 00545 and 00638 Stored in DTC Memory 01 07 01 Jan. 8, 2007, 2004396, Supersedes Technical Bulletin Group 01 number 97-13 dated May 23, 1997 due to inclusion into ElsaWeb. Technical Background May be caused by: - Incorrect Engine Control Module (ECM) coding (codeable ECM only). - Wiring harness and/or connections between Transmission Control Module (TCM) and ECM.Malfunctioning ECM. - Intermittent continuity in engine harness. - Poor engine compartment ground (GND). Production Solution Not Applicable. Service If vehicle exhibits this condition use the following table as a guide for repairs: - Erase DTC memory, road test vehicle and recheck for any stored DTC's. Warranty Information only. Required Parts and Tools No Special Tools required. No Special Parts required.Always see ETKA for the latest part(s) information. Page 2861 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation Locations Steering Mounted Controls Communication Module: Locations J453 - Control module for multi-function steering wheel Page 1772 Engine Oil: Service and Repair For further information regarding this component please refer to Lubrication Systems; Service and Repair. Page 182 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Page 1390 Impact Sensor: Locations Crash Sensor For Side Airbag, Passenger Side G180 - Crash sensor for side airbag, passenger side Page 1219 - Disconnect white 3-pin harness connector to knock sensor 1 (arrow). Knock Sensor (KS) 2 -G66- Disconnect brown 3-pin harness connector to knock sensor 2 (arrow). - Measure resistance between knock sensor terminals -1- + -2-, -1- + -3- and Specified value: infinity ohms - Remove wiper arms and plenum chamber cover. If the specification is not obtained: - Replace Knock Sensor (KS) 1 -G61- or replace Knock Sensor (KS) 2 -G66-. Refer to item 15 or item 11 under "Ignition System", See: Powertrain Page 312 - Open hood and place fender cover in position - Disconnect the ground cable (GDN) from the negative (-) battery terminal - Disconnect electrical connector -1- from mass air flow sensor -2- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only) - Remove clamp -3- and disconnect intake air hose from mass air flow sensor - If applicable, remove secondary air hose -4- from air filter box -5- Remove screws -6- securing air filter box and remove air filter box - If applicable, remove and move aside secondary air relay box and harness from supporting clip - If applicable, disconnect electrical connector on brake fluid reservoir - Release ABS control module electrical connector by pulling latch upward -arrow 1- Pull electrical connector off ABS control module -arrow 2- Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws - Lower vehicle - Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle - Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor - Raise vehicle - Close left front and left rear caliper bleed screws when brake fluid stops flowing - Lower vehicle - Do not remove brake pedal depressor from brake pedal at this time NOTE: By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system - Place sufficient lint-free cloths under the ABS control module and hydraulic unit Page 5796 3 - Securing lever Installing - Insert ignition key in lock cylinder and turn to position "Drive". - Release securing lever using wire (approx. dia. 1.2 mm) and insert lock cylinder in steering lock housing. NOTE: - Where applicable, ensure immobilizer induction coil electrical connection orientation in lock cylinder housing guide. - Pull wire out of lock cylinder and ensure lock cylinder is secured properly in steering lock housing. - Reconnect immobilizer reading coil electrical connector -arrow- to lock cylinder. - Install steering column switches and steering wheel. Page 1525 Page 1861 The display will show the following message: "service ---". - Turn the ignition off. Only then, the next service indicator will be updated. Reset the service interval indicator with the Diagnosis, Measurement and Information SystemVAS 5051A /52 Special tools, testers and auxiliary items required - Diagnosis, Measurement and Information System VAS 5051A /52 - Diagnosis cable VAS 5051/3 - Operate the parking brake. - Automatic transmission: Position the selector lever in "P" or "N". - Mechanical transmission: selector lever at dead center. - Turn the Vehicles diagnosis, measurement and information system VAS 5051 on. - Turn the ignition on. The display shows: - On the display, press the "Vehicle self-diagnosis" key -arrow-. Page 5710 Volkswagen Canada, Inc. A/T - AG4 Slips on 2nd to 3rd Gear Shifts Control Module: Customer Interest A/T - AG4 Slips on 2nd to 3rd Gear Shifts Group: 37 Number: 03-01 Date: July 23, 2003 Models: ALL with 2.8L VR6 (Eng. Code AFP) 1999--> 2002 Subject: Automatic Transmission, Slips When Shifting from 2nd to 3rd Gear Condition Transmission slips and then shifts hard into gear during the 2nd to 3rd shift. May be caused by Transmission Control Module (TCM) software. Service If transmission diagnosis does not indicate repairs are necessary: - Install new TCM Part No: 01M 927 733 MP, (software level 5060). - The "MP" suffix part supersedes Part No: 01M 927 733 with suffix-DJ, JS, KR, MB and MH. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. After TCM replacement, using the VAS 5051 or VAS 5052: - Check and erase Diagnostic Trouble Codes (DTCs). - Set Basic settings. With Manufacturer's Scan Tool Knock Sensor: Testing and Inspection With Manufacturer's Scan Tool Knock Sensors, Checking NOTE: - It is extremely important to keep to the tightening torque of 20 Nm (15 ft lb) to ensure the knock sensors function normally. - Only gold plated terminals may be used when servicing the knock sensor harness connector terminals. Special tools and equipment - VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool with VAG1551/3 adapter cable - VAG1598/31 test box - Multimeter (Fluke 83 or equivalent) - VW1594 adapter set - Wiring diagram Test conditions - The On Board Diagnostic (OBD) must have recognized a malfunction of one or both knock sensors. - Coolant temperature must be at least 85 °C See display group 28, display field 3. Checking function - Connect VAG1551 Scan Tool (ST) or VAG1552 mobile scan tool. Start engine and press buttons -0- and -1- to select "Engine Electronics" address word 01 (when doing this engine must be running at idle speed). Indicated on display: Rapid data transfer HELP Select function XX Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input. Indicated on display: Read Measuring Value Block Input display group number XXX - Press buttons -0-, -2- and -8- to input display group number 28 (028), and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) Read Measuring Value Block 28 -> 1234 NOTE: Checking the knock sensors must be performed during a road test because the diagnostic of the knock sensors is not activated until the engine speed exceeds 2000 rpm and the engine is under more than a 40% load. - Carry out road test and check knock control Specified values on display (display fields 3 and 4). Observe the valid safety precautions when carrying out a road test. Refer to "Ignition System/Service Precautions", See: Ignition System/Service Precautions/Technician Safety Information Page 2245 T 40005 - Audi Cam Align. Tool Page 1251 - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Battery voltage must be at least 11.5 volts. - All electrical consumers like, for example, lights and rear window heating must be switched off. - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - If vehicle is equipped with an A/C system, it must be switched off. - Ground (GND) connections between engine and chassis must be OK. - Exhaust system must be properly sealed between catalytic converter and cylinder head. - Coolant temperature must be at least 80 degree C, Diagnostic mode 1: Check measuring values; PID 5, Coolant temperature. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 1: Check Measured Values - Oxygen sensor heater for oxygen sensor behind catalytic converter must be OK. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor Heater For O2 Sensor After TWC, Checking Function test - Select the output of oxygen sensor signals and check whether the specified values are being reached, Diagnostic mode 5: Check output of oxygen sensor signals. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 5: Check Output of Oxygen Sensor Signals If specified values are obtained: - End diagnosis and switch ignition off. If specified values are not obtained: - End diagnosis and let engine continue to run at idle. - Check primary voltage. Checking primary voltage - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 821 - Check wiring between test box and 4- pin harness connector for open circuit according to wiring diagram. - Terminal -1- + socket 108 - Terminal -3 + socket 93 Wire resistance: max. 1.5 ohms - Check wire between test box and 4- pin harness connector terminal -1- for short to wire terminal -3- or to vehicle Ground (GND) according to wiring diagram. - Terminal -3- + socket 108 - Terminal -3- + vehicle Ground (GND) - Specified value: infinity ohms - Additionally, check both wires for short to battery positive (B+). Specified value: infinity ohms If no malfunction is found in wiring: - Perform resistance measurement on Engine Coolant Temperature (ECT) sensor -G62-, terminal -1- (Ground (GND)) and terminal -3- (signal). Page 4875 - Insert over-center spring into rear mounting first (arrow -B-), then operate clutch pedal until the retaining clamp seats on the mounting lug of the clutch pedal (arrow -A-). - Take out retaining clamp while moving clutch pedal to rest position. Page 4397 - Check Ground connections for corrosion and poor contact; repair if necessary. Ground connection point is located under battery. - Check battery Ground strap and Ground strap between battery and transmission. - Switch ignition off, release multi-pin connector and disconnect control module. - Connect test box V.A.G 1598/18 to multi-pin connector (1) and lock in direction of arrow (2). Using the test box V.A.G 1598/18 the wiring can be checked according to the wiring diagram. NOTE: - Before connecting test leads the correct measuring range on the tester must be adjusted. Otherwise the electronic components can be destroyed! - Use the multimeter V.A.G 1526 with auxiliary cables from V.A.G 1594 for testing. - The specified values are valid for an ambient temperature from 0 °C to 40 °C. - If the readings obtained differ from the specified values, determine what is faulty on the basis of the wiring diagram. - If the readings obtained differ only slightly from the specified values, clean sockets and connectors of the testers and test leads and repeat test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on component. Socket assignment on control module connector Page 5618 Page 429 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 1252 - Connect multimeter for voltage measurement to terminals 3 + 4 of connector to Engine Control Module (ECM) and measure primary voltage. Specified value: 0.40 to 0.50 Volts - Switch ignition off. If specified value is not obtained: - Test oxygen sensor wires. If specified value is obtained: - Replace Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- Bank 1: Vehicles with engine code AFP, item 9, - Vehicles with engine code BDF, item 13. - Erase DTC memory of Engine Control Module (ECM), Diagnostic mode 4: Reset/erase diagnostic data. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Scan Tool Testing and Procedures/With Generic Scan Tool/Diagnostic Mode 4: Reset/Erase Diagnostic Data - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Checking oxygen sensor wires - Connect test box to control module wiring harness, connect test box for wiring test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. 4 Speed Automatic 01M Data Link Connector, A/T: Locations 4 Speed Automatic 01M Data Link Connector (DLC) Location: The DLC (arrow) is located behind a cover under the left side of the instrument panel. Page 1191 - Generate readiness code. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes If no malfunctions are detected in the wires and the resistance values are OK: - Replace Motronic Engine Control Module (ECM) -J220-. Page 4627 Downshift Switch: Description and Operation 4 Speed Automatic 01M Kickdown switch -F8For On Board Diagnostic (OBD) On vehicles without an accelerator cable, the kick-down switch signal is transmitted from the engine control module to the automatic transmission control module. On vehicles with CAN-bus the automatic transmission control module receives the kick-down signal from the CAN bus. On vehicles without CAN-bus, the signal is received via a wire from the engine control module. Page 206 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) General Information Battery: Application and ID General Information General Information NOTE: Several different types of battery may be installed on Golf/Jetta vehicles. Each requires specific servicing: - Batteries with charge indicator ("magic eye") and foil sealed cell caps. See: Testing and Inspection/Component Tests and General Diagnostics/Low Maintenance Batteries, Checking - Batteries with charge indicator ("magic eye") without cell caps. See: Testing and Inspection/Component Tests and General Diagnostics/Maintenance Free Batteries, Checking - Batteries without charge indicator. See: Testing and Inspection/Component Tests and General Diagnostics/Battery Without Charge Indicator (Magic Eye), Checking - For identification purposes, the following battery type definitions establish the technical differences between the two installed battery types. Battery type definitions - Low Maintenance Batteries: Lead-antimony coated electrodes (plates). With or without charge indicator. Electrolyte filling caps accessible. - Maintenance Free Batteries: Lead-Calcium coated electrodes (plates). With charge indicator. Electrolyte filling caps not accessible. Page 5595 Page 4270 ^ Updated software level "0003", "0004", "0005", "0007" or "0009" (depending on ECM Part No.) will appear at (arrow). ^ Flash CD can now be removed from VAS 5051 or VAS 5052 Diagnostic tool. - Print the ECM screen to verify ECM update software level. ^ VAS 5051 will print to printer immediately. ^ VAS 5052 will hold the print until process is complete and then you may take the tester to the printer for printing the screen. - Attach print to vehicle Repair Order. - Select "Go to" then select "Exit". Note: It is not generally necessary to encode the ECM following the "update - Programming" (flashing procedure. However, you must set the readiness code. - Set readiness code. ^ Use VAS 5051 or VAS 5052 to set readiness code. When procedure applies to vehicles within the New Vehicle Limited Warranty, see the table. Specifications Oil Pressure Sender: Specifications Switch - Tightening Specifications Switch - Tightening Specifications 0.3 Bar Switch (Brown) 20 Nm 1.4 Bar Switch (Black) 25 Nm Page 5159 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 86 - Antenna cables - Touareg 2004 > 2006 Tip: Part numbers listed in this bulletin are for reference only Always check with your Parts Dept. for the latest parts information. Page 985 ^ This switch can be identified by the larger (approx. 10 mm) plunger tip and square shaft (arrow). - Remove brake switch by turning left 90° Install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511D: Installing below). Brake switch, Part No: 1J0 945 511B, C or D, removing: ^ These switches can be identified by the smaller (approx. 4 mm) plunger and round shaft (black arrow). - Remove brake switch by turning left 45° When replacing after removal, install revised switch Part No: 1J0 945 511D (see Brake switch, Part No: 1J0 945 511 D: Installing below). 2. Brake switch, Part No: 1J0 945 511 D: Installing: CAUTION! This version switch contains an internal switch which can be damaged if not installed and adjusted properly. DO NOT depress plunger prior to installation. Page 5838 Part 3 Circuit and Terminal Designations Several wiring circuits in the vehicle's electrical system are identified with a number or letter designation. These circuits are identified the same in all wiring diagrams and are most commonly shown near the top of each page in the fuse/relay panel portion of the wiring diagram. The circuit designations may also be used to identify switch connector terminals (switch circuits). Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Page 1212 - Also check wires for short circuit to each other, to vehicle Ground (GND) and to B+. Specified value: infinite Ohm If no malfunctions are found in wire: Vehicles with engine code AFP - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Vehicles with engine code BDF - Measure resistance at Intake Air Temperature (IAT) Sensor -G42-, terminals 1 (signal) and 3 (Ground -GND-). Continuation for all vehicles Range A displays resistance values for the temperature range of 0...50 degree C, range B displays resistance values for the temperature range of 50...100 degee C. Read-out examples: - 30 degree C is in range A and corresponds to a resistance of 1.5 to 2.0 kOhms - 80 degree C is in range B and corresponds to a resistance of 275 to 375 Ohm If specified value is not obtained: - Replace Mass Air Flow (MAF) Sensor -G70-: Vehicles with engine code AFP, item 4, - Vehicles with engine code BDF, item 6. Page 5022 Fig. 1 Separating cover from gear shift knob and assembling to gear shift knob Turn boot inside out. - Carefully pry clamping sleeve (arrow) off with a screwdriver and pull gear shift knob out. Installation is carried out in the reverse sequence. Also, note the following: Insert gear shift knob in cover. - Push clamping sleeve onto gear shift knob and engage. - Install gear shift knob and boot together. Page 1245 - The O2S sensor has been damaged by leaded fuel Checking basic voltage for oxygen sensor 2 - Remove protective cover (arrows) and disconnect 4-pin harness connector (brown) -1 - to oxygen sensor after Three Way Catalytic Converter (TWC) -G130-. - Connect multimeter using auxiliary cables from VW1594 to measure voltage at terminals 3 + 4 (harness connector to Motronic Engine Control Module (ECM)). - Start engine and measure basic voltage. Specified value: 0.400-0.500 V - Switch ignition off. If the specified value is not obtained: - Check oxygen sensor wiring. If the specified value is obtained: - Replace oxygen sensor behind Three Way Catalytic Converter (TWC) -G130-. Refer to item 28 under "Fuel Delivery and Air Induction/Fuel Injector", See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. Checking oxygen sensor wiring, oxygen sensor 2 - Remove wiper arms and plenum chamber cover. Page 1297 WHAT ARE TRACKS? Tracks are navigational aids, like the grid lines on a map, but they are invisible on the diagrams. They are only identified by numbers at the bottom of the diagram. The diagram wires/circuits are laid out over these imaginary vertical lines, and each diagram is identified by the range of tracks it is laid over, not by the diagram's contents (i.e. Track 1-14, Track 15-28, and so on). HOW DO THE WIRES/CIRCUITS WORK WITH THE TRACKS? Wires/Circuits that do not originate/terminate on the same diagram will have a notation of where they are coming from/going to at either end. Wires/Circuits entering/leaving the diagram in a horizontal direction will pick up again on the previous/next diagram in the series. However, wires/circuits traveling the diagram in a vertical direction are following the tracks, and when they enter/leave a diagram they could be skipping A/T - Slips On 2-3 Upshift Control Module: All Technical Service Bulletins A/T - Slips On 2-3 Upshift 37 07 05 2005572 Jan. 16, 2007 37 07 05 Jan. 16, 2007 Supersedes Technical Bulletin Group 37 number 03-01 dated July 23, 2003 Condition Vehicle Information Technical Background May be caused by Transmission Control Module (TCM) software. Production Solution Not Applicable. Service If transmission diagnosis does not indicate repairs are necessary: ^ Install new TCM Part No: 01M927733MP, (software level 5060) ^ The "MP" suffix part supersedes Part No: 01M927733 with suffix - DJ, JS, KR, MB and MH. After TCM replacement, using the VAS 5051 or VAS 5052: ^ Check and erase Diagnostic Trouble Codes (DTCs). ^ Set Basic settings. Warranty Required Parts and Tools Page 1751 Engine Oil: Technical Service Bulletins Engine - Oils Meeting Manufacturer's Standard 17 09 07 June 30, 2009 2012855 Supersedes T.B. Group 17 Number 09-05 dated March 30, 2009 due to reorganization of attached world wide oil specifications list to eliminate confusion. Vehicle Information Condition Engine Oils Which Meet Volkswagen Oil Quality Standards VW 502 00, VW 505 01 and VW 504 00/507 00 (U.S. ONLY) Technical Background Information only. Production Solution No production change required. Service Attached is a Worldwide list of engine oils which currently meet Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00. TIP: SOME ENGINE OILS LISTED ON THE ATTACHMENT MAY NOT BE AVAILABLE IN NORTH AMERICA. Please refer to the specific Vehicle Owner's Manual, published Technical Bulletins and Fluid Capacity Charts to select the appropriate oil required for each Volkswagen vehicle. The sample list below are products generally available in the North American market that meet Volkswagen Oil Quality Standard VW 502 00, VW 505 01 and VW 504 00/507 00 specification at the time of this publication. Page 5614 <-- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit ^ Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION! DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE <-- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) ^ Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws Note Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation ^ Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs) Note Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean ^ Remove yellow plastic plugs and red bracket from hydraulic unit ^ Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) ^ Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on atleast2morevehicles.Only one repair kit will be allocated for every 3 vehicles ^ Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) ^ Remove lint-free clothes from under the ABS control module and hydraulic unit Page 3002 - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation If the idle speed is not obtained: - Carry out adaptation of Engine Control Module (ECM) to throttle valve control module. See: Computers and Control Systems/Engine Control Module/Testing and Inspection - Carry out road test. Observe the valid safety precautions when carrying out a road test. See: Fuel Delivery and Air Induction/Service Precautions/Technician Safety Information - Check DTC memory again. - Repeat idling check. If the specified values are not obtained again: - Check throttle valve control module. - Check intake air system for unmetered air. - Check operating condition of engine. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Engine Operating Conditions, Checking - Check signals from/to air conditioner. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/A/C Compressor Signal, Checking Page 5363 - Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit - Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop CAUTION: DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE - Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.) - Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws NOTE: Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation - Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs.) NOTE: Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean - Remove yellow plastic plugs and red bracket from hydraulic unit - Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.) - Clean all debris and contaminants from all removed plugs and bracket IMPORTANT: Save all the plugs and plastic bracket. They can be used on at least 2 more vehicles. Only one repair kit will be allocated for every 3 vehicles - Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.) - Remove lint-free clothes from under the ABS control module and hydraulic unit Place electrical connector -1- into ABS control module and push in direction of -arrow 2- Lock electrical connector to ABS control module by pushing latch down -arrow 3- If applicable, reinstall secondary air relay box and reinsert harness in support clip - If applicable, reconnect electrical connector to brake fluid reservoir System Pressure Fuel Pressure: Specifications With Hose to Regulator Connected approx. 2.5 bar With Hose to Regulator Disconnected approx. 3.0 bar Page 1924 VW/Audi axle nut set. Contains:6500-14, 6500-17, 6500 X-30, and 6500 X-32. - 14mm allen for VW Passat 1996-2001, Audi A4; front and rear axle bolts (AWD) - 17mm allen for 1998-2005 VW Passat, 1999-2004 Audi A6, 2002-2005 Audi A4; front and rear axle bolts (AWD) - 30mm 12 point socket for mid 1999-2005 VW Golf, Jetta, Cabrio, and Beetle; front axle nut - 32mm 12 point socket with a 3/4" drive, VW Touareg; front and rear axle nuts Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: 6500-14 - 14mm Allen Socket Page 4054 - Remove engine cover. - Disconnect connector from ignition coils 1 to 6. NOTE: Before disconnecting harness connectors, mark allocation to component. Checking voltage supply - Measure supply voltage between terminals 1 + 3 and 2 + 3 of disconnected connector using the multimeter and adapter cables. - Switch on ignition. Specified value: at least 11.5 V - Switch ignition off. If there is no voltage: - Check wire between 4-pin connector terminal 3 and Motronic Engine Control Module (ECM) Power Supply Relay -J271- for open circuit according to wiring diagram Wire resistance: max: 1.5 Ohms - Check wires between 4-pin connector and Ground (GND) for open circuit according to wiring diagram. Terminal 1 and Ground (GND) Terminal 2 and Ground (GND) Wire resistance: max: 1.5 Ohms Page 3746 Air Injection Control Valve: Testing and Inspection Secondary Air Injection (AIR) Valve, Checking With Manufacturer's Scan Tool Secondary air valve, checking Special tools, equipment, test and inspection devices; required accessories - VAG 1594 A auxiliary measuring tool set - VAG 1527 B diode test lamp Test condition - Coolant temperature 5 - 33°C - Air pump motor OK. Test sequence - Pull upper vacuum hose -arrow- of secondary air valve. - Start motor and let it idle. Service and Repair Parking Pawl: Service and Repair 4 Speed Automatic 01M Parking lock, disassembling and assembling Special tools and equipment - VW 222 A Drift - VW 228 B Puller - VW 423 Tube - VW 460/2 Mandrel Note: The output gear must be removed to disassemble and assemble the parking lock. Service and Repair Accelerator Pedal Position Sensor: Service and Repair 1 - Bracket Removing and installing 2 - Connector Black, 6-way 3 - 10 Nm 4 - Throttle position sensor for accelerator position (G79) Not adjustable - The throttle position sensor passes the driver action to the engine control module - To remove the sensor, remove the cover in the footwell - Check 5 - Bracket For the footwell cover - Clipped tight on the throttle position sensor Page 5466 ^ Using a screwdriver, lift cover of multi-pin connector and remove. ^ Using a small screwdriver, push purple latch in direction of arrow. Pin assignment of harness connector T25 and ABS Control Module (W/EDL) -J104 Pin Connected to component: 19 + 20 Right Front ABS Wheel Speed Sensor -G45 1 + 2 Left Front ABS Wheel Speed Sensor -G47 5 Speed Automatic 09A Transmission Position Switch/Sensor: Locations 5 Speed Automatic 09A Tiptronic switch -F189- Location: The switch is on the printed circuit of the symbol insert, which is located in the selector mechanism cover. - It consists of 3 Hall sensors, which are actuated by solenoids - The switch can be checked in the measured value block and electrically. - If malfunctions occur in the switch, the symbol insert must be replaced with the printed circuit. Page 2158 - Check securely seated 16 - Change-over barrel Intake Manifold Lower Section Intake Manifold Lower Section, Disassembling and Assembling 1 - Cable guide Clipped onto fuel rail 2 - 10 Nm (7 ft lb) 3 - Fuel rail 4 - Supply connection 5 - Return flow connection 6 - Intake manifold lower section 7 - Seal Always replace 8 - To intake hose For air circulation of fuel injectors 9 - Bracket For Secondary Air Injection (AIR) pump motor -V101- and secondary air inlet valve: - Secondary air system: 10 - 25 Nm (18 ft lb) 11 - O-ring Always replace if damaged - Before installing, moisten with clean engine oil 12 - Injectors -N30- through -N33-, -N83- and -N84-* Air shrouded - Checking. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Testing and Inspection 13 - Retaining clip Check securely seated 14 - Vacuum connection To T-piece connection non-return value/intake manifold upper section 15 - Fuel pressure regulator Checking. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pressure Regulator/Testing and Inspection Page 6498 Use grease packet from repair kit Pressing wheel bearing into wheel bearing housing - Install circlip. Note: Make sure the circlip is seated correctly. The opening of the circlip must point downward. Pressing wheel hub into wheel bearing Pressing Front Wheel Bearing Out and In With Wheel Bearing Housing Installed Pressing Front Wheel Bearing Out and In with Wheel Bearing Housing Installed Page 3378 Oxygen Sensor: Testing and Inspection Oxygen Sensor Heater For O2 Sensor After TWC, Checking With Manufacturer's Scan Tool Refer to Oxygen Sensor And 02 Sensor Control After TWC, Checking, With Manufacturer's Scan Tool. See: Testing and Inspection/Component Tests and General Diagnostics/Oxygen Sensor and O2 Sensor Control After TWC, Checking/With Manufacturer's Scan Tool With Generic Scan Tool Oxygen Sensor Heater For Oxygen Sensor Behind Three Way Catalytic Converter (TWC), Checking NOTE: - Vehicle must be raised before connector for oxygen sensor is accessible. - When servicing terminals 3 and 4 in harness connector of Heated Oxygen Sensor (HO2S), use only gold-plated terminals. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- must be OK. - Ignition switched off. Test sequence - Unscrew protective cover (arrows) and disconnect 4-pin harness connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-. Page 2236 If TDC cyl. 1 position is correct, it will be possible to see a slot -arrow- on the sprockets of the intermediate shaft. Note: This condition is only reached in every second TDC position. If the groove cannot be seen: Turn crankshaft one turn further in direction of rotation of engine. It must be possible to insert camshaft guide 3268 into both shaft slots. Page 5033 - Smear a small amount of polyurea grease in recesses of cable locking mechanism -A- and gate cable locking mechanism -B-. Note: The seals -arrows- outside the recess must be grease free. - Press gear selector cable onto transmission selector lever and gate selector cable onto relay lever (arrows). Selector mechanism from 01.01 The cable locks have holes for securing them on the gear selector lever or the relay lever. The holes in the cable locks have various diameters. Page 1424 Ignition Switch Lock Cylinder: Service and Repair Lost Key Procedure Lost Key Procedure - Order replacement ignition key using lock number. - Adapt all available ignition keys. Secret number, determining If the 4-digit secret number is not known or the new vehicle key fob with the secret number is not available, the secret number must be requested from the corporate radio/immobilizer code retrieval system by supplying the 14- character immobilizer control module identification number. - Initiate OBD of instrument cluster. - Read 14-character immobilizer identification number: Indicated on display (example only) IMMO-IDENT No.: VWZ7ZOV0066808 -> Page 3164 - Use wiring diagram to check cables between test box and connector for any broken connections. Contact 1 + cavity 72 - Contact 2 + cavity 73 - Contact 3 + cavity 36 - Contact 4 + jack 35 - Contact 5 + jack 33 - Contact 6 + jack 34 - Line resistance: max. 1.5 Ohms - Also check cables for a short circuit to battery positive terminal or to ground. - Also check cables for short circuits between each other. If no problems can be found in the cables: - Replace throttle position sensor (G79), item -4-. Page 3544 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection With Generic Scan Tool Engine Coolant Temperature (ECT) Sensor, Checking NOTE: Use only gold-plated terminals when servicing terminals in harness connector of sensor. Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements - The respective fuses of Motronic Engine Control Module (ECM) -J220- must be OK: - Parking brake must be engaged or else daylight driving lights will be switched on. - For vehicles with automatic transmission, selector lever must be in position -P- or -N-. - Engine must be cold. Function test - Connect diagnostic tester. See: Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Diagnostic Tester, Connecting - Switch ignition on. - Under address word 33, select "Diagnostic mode 1: Checking measured values." - Select the measuring value "PID 05: Coolant temperature". - Check specified value of coolant temperature: If specified value is not obtained: - Continue test according to the following table: Indicated1) Cause approx. -40 degree C Open circuit or short circuit to B+ approx. 140 degree C Short circuit to Ground (GND) 1) If a temperature is indicated which differs greatly from ambient temperature of sensor, check sensor wires for contact resistance. If specified value is obtained: - Start engine and let run at idle. The temperature should climb uniformly NOTE: - The temperature increases in increments of 1.0 degree C. - If the engine shows problems in certain temperature ranges and if the temperature does not climb uniformly, the temperature signal is intermittent and the sensor should be replaced. M/T - Humming Noise When Turning at Low Speeds Fluid - M/T: All Technical Service Bulletins M/T - Humming Noise When Turning at Low Speeds 34 06 02 June 12, 2006 2011899 Affected Vehicles Supersedes TB Group 34 number 06-01 dated June 5, 2006 due to Golf model Condition Customer States Humming Sound From Front of Vehicle During Cornering Customer may state humming sound coming from front of vehicle on turns in vehicles equipped with 02J or 0A4 manual 5 speed transmission. The hum may be more noticeable during slow speed turning maneuvers with steering wheel almost to full travel. The hum diminishes with steering wheel straight. Technical Background Hum may be generated by the differential spider gear contacting the one piece thrust washer when under load. Production Solution New transmission oil Part No. G 055 726 A2 incorporated in transmission production plant. Transmissions with new oil installed begin with VINs in table. Service 0A4 Manual 5 Speed Transmission, Draining and Re-filling If the vehicle exhibits this condition, drain and re-fill transmission as follows: - It is no longer possible to accurately check transmission oil level in the same manner as previous model years. Page 37 - Antenna Selection Control Module -J515- (Diversity box) All models use an Antenna Selection Control Module -J515- item -8-. ^ Location: Behind rear section of molded headlining. Antennas All models use four antennas items -2-, 4- (qty. 2) & -7-. ^ Antennas (R130, R131) are integrated into rear hatch glass. ^ Antenna R11 in left rear side glass. ^ Antenna R93 in right rear side glass. Antenna amplifiers All models use four antenna amplifiers items -1-, -3-, -5- & -6-. ^ Item 1 - Antenna Amplifier 1 -R24- (for AM and FM reception). Above left side window. ^ Item 3 - Antenna Amplifier 2 -R111- (for FM reception). In upper section of rear lid. ^ Item 5 - Antenna Amplifier 3 -R112- (for FM reception). In upper section of rear lid. ^ Item 6 - Antenna Amplifier 4 -R113- (for FM reception). Above right side window. Phaeton Page 1022 Warranty Required Parts and Tools Page 3081 Part 1 Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find Wiring Diagrams NOTE: Wiring Diagrams are classified by OE as belonging to one of three categories. These Three OE Categories Are:: 1 - Standard Equipment 2 - Engine Specific 3 - System Specific and Optional Equipment (Common Systems) Standard Equipment This category includes equipment such as Instrument Cluster and Gauges, Headlights/Tail Lights/Turn Signals, Rear Window Defroster, Wipers and Washers, etc.. Standard equipment is found on all vehicles regardless of which engine or optional equipment is installed. The Standard Equipment diagrams can be found at Power and Ground Distribution diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. Engine Specific This category includes components and systems circuits such as Starting and Charging Systems, Engine Controls, Ignition System, Fuel Injection System, etc., which are unique to a specific engine. The Engine Specific diagrams can be found at Powertrain Management diagrams, or via a component name on the Master Diagram Index at the vehicle level diagrams. System Specific and Optional Equipment This category includes equipment such as Air Bag Systems, Anti-lock Brake System, Heated Seats, HVAC System, Comfort System, etc.. and provides circuit details for those systems and components. Master Diagram Index See: Diagrams/Electrical Diagrams/Master Diagram Index How to Read Track Diagrams Page 260 Page 2552 Thermostat Housing: Service and Repair Thermostat housing, disassembling and assembling Note: Routing of hoses at the coolant controller housing. 1. Plug 2. O-Ring - Always replace 3. Gasket - Always replace 4. Retaining clamp - Check for tight fit 5. Thermostat housing 6. 10 Nm 7. Thermostat - Install position: large plate downward - Checking: heat controller in water bath - Opening starts at approx. 80°C - Opening ends at approx. 105°C - Travel at least 7 mm 8. Connector 9. 10 Nm 10. Coolant temperature sensor (G62) - With coolant temperature display sensor (G2) Page 489 Display Group 062 - Depress accelerator slowly until Wide Open Throttle (WOT) position and observe angles displayed in display fields 1 and 2. The percentage displayed in display field 1 must rise continuously and evenly. The full tolerance range (3-93%) is not always displayed. The percentage displayed in display field 2 must fall continuously and evenly. The full tolerance range (97-3%) is not always displayed. NOTE: - The display in display field 1 rises and the display in display field 2 falls because the potentiometers (angle sensors) in the throttle valve control modules run in opposite directions. - This means that the voltage of one angle sensor moves toward 5 volts (the more the throttle valve is opened the higher the voltage; percentage increases), while the voltage of angle sensor 2 drops from 5 volts toward 0 volts (the more the throttle valve is opened the lower the voltage; percentage falls). If the specified values are obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Page 4705 Shift Interlock Solenoid: Service and Repair 5 Speed Automatic 09A Shift lock solenoid -N110-, removing and installing Removing Check whether a coded radio is fitted. If so, obtain anti-theft coding. - Shift selector lever into "P" position. - Switch ignition off and disconnect battery Ground strap. - Raise vehicle. - Unbolt retainer from catalyst on subframe and pull to rear. Loosen double clip. Note: Do not remove catalyst. Leave on subframe. - Remove selector lever from retainer on front heat shield. - Remove front tunnel heat shield. - -Loosen center tunnel heat shield and slide to rear. - Unscrew 4 nuts -arrows A-. - Unscrew two bolts -arrows B-. - Carefully slide cover with protective sleeve to front over selector lever cable. Note: Be careful not to damage protective sleeve. - Unclip shift lock solenoid -N110- from retainer arrows A-. - Pull solenoid out of locking pawl -arrow B-. Page 4407 - Release control module connector and disconnect. - Connect VAG 1598/18 test box to multi-pin connector -1- and lock in direction of arrow -2- Using VAG 1598/18 the wiring can be checked according to the wiring diagram. CAUTION! In order to avoid interference with electronic components, switch to the correct test range on the multimeter before connecting the test leads. NOTE: - For testing use a Fluke 83 multimeter or equivalent with auxiliary wiring from VAG 1594. - The specified values are valid for an ambient temperature from 0 °C - 40 °C (50 - 104 °F). - If measured values differ from the specified values, determine the malfunction using the appropriate wiring diagram. - If measured values differ only slightly from the specified values, clean the sockets and connectors of the testers and test leads and repeat the test. Before replacing the particular components, test wiring and connections and, particularly if specified values are below 10 Ohms, repeat resistance measurement on the component. After electrical checks: Page 1862 Note: In case the operations are not shown on the display: Diagnosis, measurement and information system instruction manual for vehicles VAS 5051. The display shows: - On the display, press the "17 Instrument panel" -arrow-. The display shows: The command unit identification and the code -arrow- : - On the display, press direction key -1-. Page 5537 Required Parts and Tools No Special Parts required. Additional Information All part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check with your Parts Dept. and Repair Manuals for the latest information. Page 3397 numerous diagrams in the series before picking up again on the destination diagram. When these wires/circuits enter or leave a diagram, the track number of the diagram they came from/go to will be shown within a continuation reference frame/box. HOW DO I NAVIGATE THE DIAGRAMS VIA THE TRACK NUMBERS? Track 1-14 Assume you are tracing the wire/circuit identified by its size and color as 2,5 sw/ro on the diagram named Track 1-14. This wire/circuit is running on track 8 of the diagram and terminates at the box labeled 175. To continue tracing this wire/circuit, you must now go to Track 175, which is located within the diagram named Track 169-182. But before going to the diagram named Track 169-182, again make note of the current track that you are leaving, which is Track 8. Track 169-182 After arriving at the diagram named Track 169-182, locate track 175 at the bottom of the diagram. Follow the imaginary track 175 grid line toward the top of the diagram looking for a box labeled 8 (the track you are coming from). When you locate the box labeled 8, you have picked up the continuation of wire/circuit 2,5 sw/ro and can continue to trace it until it terminates at either a component or at yet another continuation reference box. NOTE: It is equally important that you always know the track that you are coming from as well as the one you are going to. Symbols Used In Wiring Diagrams Page 3371 Display Group 041 If the specified value is obtained: - Press -> button. - Press buttons -0- and -6- to select "End Output" function 06 and press -Q- button to confirm input. - Switch ignition off. Continuation Page 2710 - Connect VAG1598/31 test box to Engine Control Module (ECM) wiring harness. Engine Control Module (ECM) is not connected by this action. Checking voltage supply terminal 30 - Measure supply voltage between test box sockets 1 + 62 using multimeter and adapter cables from VW1594: Specified value: at least 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from battery (B+) voltage, the readiness code must be generated again. Checking voltage supply terminal 15 - Measure supply voltage between test box sockets 2 + 3 using multimeter and auxiliary cables from VW1594. - Switch ignition on. Specified value: min. 11.5 V If the specified value is not obtained: - Check wiring connections to relay plate according to wiring diagram. - Check DTC memory. If necessary, repair any malfunctions and erase DTC memory. - Display readiness code. If DTC memory has been erased or the Engine Control Module (ECM) was disconnected from permanent battery (B+) voltage, the readiness code must be generated again. With Generic Scan Tool Voltage Supply For Engine Control Module (ECM), Checking Recommended special tools and equipment - VAG1526 multimeter or VAG1715 multimeter - VAG1594 connector test kit - Wiring diagram Test requirements Page 1688 - Always replace seal (arrow) when checking ATF level. ATF LEVEL, CHECKING Checking Conditions - Transmission not in emergency run mode, ATF temperature not above approx. 30° C (86° F). - Vehicle level. - Selector lever in "P". - Remove noise insulation tray. - Remove noise insulation from left long member. - Attach VAG 1924 ATF filling system reservoir to vehicle. - Connect VAG 1 551 scan tool and enter address word "02 Transmission electronics". Advance until "Select function XX" is indicated on display. - Start engine. - Raise vehicle. - Place container under transmission. 4 Speed 01M Transmission Fluid - A/T: Service and Repair 4 Speed 01M Transmission ATF, Replacing - Remove sound insulation tray. - Remove sound insulation from left front longitudinal member. - Place container under transmission. - Remove ATF level plug from transmission oil pan. - Remove overflow pipe (2) through level hole. - Drain ATF. - Install overflow pipe. - Screw level plug in hand-tight. - Fill with 3 liters of ATF through filler pipe using VAG 1924. - Start engine and shift through all selector lever positions with vehicle stationary. - Check and top off ATF level. Page 640 Test Step 1 - 2 Page 207 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 247 Trunk / Liftgate Relay: Locations Relay Arrangements on the Thirteenfold Auxiliary Relay Panel, Above Relay Panel Relay arrangements on the thirteenfold auxiliary relay panel, above relay panel Page 6112 Fuse: Fuse and Fusible Link Locations Fuse Arrangements In Fuse Holder, Instrument Panel Left Page 145 20 - Central control module - Bolted to bracket on steering column under instrument panel - To remove, remove lower steering column trim first 21 - Hood lock Contact switch for anti-theft alarm - Installation position: In lock carrier Page 84 - Antenna cables - double DIN (Premium VI) radio. - Antenna cables - Phaeton 2004 > 2006 - Antenna cables - Satellite radio (Hard top vehicles) 5 Speed Automatic 09A Control Module: Testing and Inspection 5 Speed Automatic 09A Control Module Pin Out Values Transmission Electrical Check Special tools and equipment - V.A.G 1526A multimeter - V.A.G 1594A Adapter set - V.A.G 1598/18 Test box Test requirements: - Battery voltage in order. - Vehicle voltage supply in order. - Fuses in main fuse box OK. - Fuses 7,11,13, 15 and 31 OK. - Check Ground connections for transmission: The transmission control module (arrow) is located in the plenum chamber. Page 3908 - Connect diode test lamp to the connector terminals of the fuel injector to be checked. Continuation for all vehicles - Operate starter and test activation of fuel injector. LED should flicker. - Switch ignition off. If LED does not flicker: - Connect test box to control module wiring harness, connect test box for wiring test. See: Computers and Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Scan Tool Connecting/With Generic Scan Tool/Test Box, Connecting For Wiring Test Vehicles with engine code AFP - Check wires between test box and 2-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Vehicles with engine code BDF - Check wires between test box and 2-pin connector for open circuit according to wiring diagram. Wire resistance: max: 1.5 Ohm Continuation for all vehicles Page 2516 A/C Pressure Sensor/Switch - Cooling Fan: Testing and Inspection High Pressure Sensor G65 High Pressure Sensor, Checking The following describes manual checking of High Pressure Sensor G65 using conventional measuring tools. A guided checking procedure is also possible using the VAS 5051/5052 tester in operating mode "Guided Fault Finding". Note: The presence of G65 is engine dependant. Where G65 is not used, A/C pressure switch F129 is used instead. - Where G65 is used, its wiring circuit varies according to engine application (E.g.: some are connected to the ECM, some are not). - Always confirm system use of either G65 or F129 and applicable wiring circuit using applicable "Engine" and "Air conditioning" wiring diagrams. Special tools, testers and auxiliary items required If performing guided test, use VAS 5051/5052 - Applicable wiring diagram - VAG 1767 Ignition tester (or equivalent device capable of duty cycle measurements) - VAG 1594/A (or C) Connector test set - VAG 1598 A Test box - In cases where refrigerant system may need to be recharged, use Kent-Moore ACR (or equivalent, VAG 1885 illustrated for reference only). Prerequisites Workshop temperature: 20-30 ° C (68-86 ° F) - Engine at workshop temperature. Preparation Note: The following test procedure is only possible on vehicles where the G65 square wave signal to Coolant Fan Control (FC) Control Module J293 is Recall - ABS Control Unit Inspection/Replacement Technical Service Bulletin # WJ-CAN Date: 020301 Recall - ABS Control Unit Inspection/Replacement WJ-CAN Subject: 2001/2002 Model Year Volkswagen Golf, Jetta, GTI and New Beetle Check/Replace ABS Control Unit March 2002 Page 6356 - Press buttons -1- and -6- to enter "Steering wheel electronics" address word 16. Indicated on display: Rapid data transfer Q 16 Steering Wheel Electronics - Confirm entry with Q button. Indicated on display: Rapid data transfer Q Tester sends address word 16 Check Control Module Versions Check Control Module Versions Indicated on display example only): 1J0907487 Steering wheel electron.x28 -> Coding 00008 WSC 00000 Readout, top line - 1JO 907 487 See Control module part number - Steering wheel electron. = System designation - x28 = Software version Readout, bottom line - Coding 00008 = coding number (dependant on model and optional equipment) See: Programming and Relearning - WSC 00000 = Workshop code CAUTION! Part numbers are for reference only. Always check with your Parts Department for the latest parts information. - Press -> button. NOTE: If this message appears in the display: Rapid data transfer HELP Control module does not answer - Press the HELP button to print out a list of possible malfunction causes. - After correcting malfunctions, re-enter address word 16 for Steering wheel electronics and press -Q- button to confirm input. Indicated on display: 1JO035152 Radio 0001 -> Coding 04403 WSC 00000 - Press -> button. Indicated on display (select function): Rapid data transfer HELP Select function XX Output Diagnostic Test Mode (DTM) (Function 03) Output Diagnostic Test Mode (DTM) (Function 03) The Output Diagnostic Test Mode (DTM) is part of the electrical check. The DTC memory must be checked after the Output Diagnostic Test Mode (DTM). Output Diagnostic Test Mode (DTM), initiating Page 1045 ^ EXAMPLE of INCORRECTLY installed switch. Internal stop pin (white arrow) is NOT seated fully against outer shell (black arrow). ^ EXAMPLE of CORRECTLY installed switch. Internal stop pin (white arrow) is seated fully against outer shell (black arrow). - Connect brake switch connector. Operate brake pedal to verify proper function, then reinstall lower cover panel. CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. Page 4955 Axle Nut: Tools and Equipment VW/Audi Axle Nut Set AST tool# 6500 Page 1589 Explanation of 8 digit number block If the specified value is obtained: - Briefly increase engine speed (rev- up) and allow engine to run at idle for 2 minutes. Checking idle speed - Change to display group 056 as follows: - Press -C- button. - Press buttons -0-, -5- and -6- to input display group number 56 (056) and press -Q- button to confirm input. Indicated on display: (1-4 = display fields) System in basic setting 56 -> 1234 - Check actual idle speed in display field 1. - Check specified idle speed in display field 2. - Check operating mode in display field 4. Explanation of 5 digit number block Description and Operation Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor -G69For On Board Diagnostic (OBD): The TP sensor is one of the engine control module sensors. However, the transmission control module also requires the TP sensor signal. Therefore, the signal from the engine control module is transmitted to the transmission control module. On vehicles with CAN-bus, the automatic transmission control module receives the TP signal from the CAN-bus. On vehicles without CAN-bus the signal is made available via a wire from the engine control module. The OBD of the transmission only checks the signal, not the TP sensor! On vehicles without CAN-bus the wire for the signal is also checked. The signal can only be read in the Measured Value Block. NOTE: Always check the engine OBD when the transmission OBD indicates that the TP sensor is faulty. Service Precautions Fuel Pressure Release: Service Precautions CAUTION! The feed line is underpressure! Place clean rags around the hose connections, then reduce the pressure by disconnecting the hose very slowly and carefully. Page 4418 If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 62 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 62 on VAG 1598/18 and terminal 6 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Check wiring further. - Measure between sockets 1 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between sockets 23 and 40 on VAG 1598/18. Specification: Infinity Ohms - Measure between socket 40 on VAG 1598/18 and terminal 2 on connector. Specification: Less than 1.5 Ohms If the specifications are not obtained: Repair wiring according to the wiring diagram. If the specifications are obtained: Replace multi-function TR switch. - Install Park/Neutral Position (PNP) Relay -J226-. Page 4614 Driving in torque converter oil seal until flush Clutch Vacuum Vent Valve Switch Clutch Switch: Locations Clutch Vacuum Vent Valve Switch F36 - Clutch vacuum vent valve switch Page 3182 Relay Panel and 13-Position Relay Panel Relay Box: Service and Repair Relay Panel and 13-Position Relay Panel Relay Plate And 13 Position Relay Carrier, Removing And Installing - Remove driver's side instrument panel trim. - Remove screws -C- (2 Nm) and loosen all screwed connections -D- as necessary. - Take out central electrics -B- and relay carrier -A- out downward. Page 1487 - Pry conductor strip off solenoid valve in direction of arrow using special tool 3373. NOTE: - If the locating points are damaged the valve body must be replaced. - Installation is performed in the reverse order of removal. - Do not kink or damage the conductor strip. Page 5424 <-- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Note: The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole <-- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket ^ Remove hydraulic unit with control module from bracket and place on a clean level work bench ^ Remove the new ABS control module (1C0 907 379 J) from package <-- Insert new adaptor -3- from kit into new ABS control module <-- Push adaptor down until clips -4- snap into position CAUTION! THE ADAPTER CAN ONLY BE PRESSED BE REMOVED AGAIN WITHOUT PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED Page 2409 Part 2 Page 5361 - Place sufficient lint-free cloths under the ABS control module and hydraulic unit - Remove brake lines -3- on the side of hydraulic unit CAUTION: DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC UNIT. - MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS - From the repair kit provided (1J0 998 375) , place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2IMPORTANT: If parts from repair kit are being reused, make certain the parts are free of debris and contaminates NOTE: The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module CAUTION: DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT - Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit Page 4644 Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay Wire and Fuse Color Code Identification Wire Color Code Identification ws = white sw = black ro = red br = brown gn = green bl = blue gr = grey li = violet ge = yellow or = orange Fuse Colors: 30 A - Green 25 A - White 20 A - Yellow 15 A - Blue 10 A - Red 7,5 A - Brown 5 A - Beige 3 A - Violet Wire Size Conversion Wire Size Conversion Chart Wiring Diagrams identify wires by the metric wire size. Metric wire sizes indicate cross-sectional area in square millimeter (mm sq.). The chart below lists metric wire sizes and their equivalents in American Wire Gauge (AWG) sizes. Page 5337 Owner Letter Page 1461 Transmission Position Switch/Sensor: Adjustments 5 Speed Automatic 09A Multi-function transmission range (TR) switch -F125-, removing, installing and adjusting Special tools and equipment - T10091 Adjusting device - V.A.G 1331 Torque wrench or equivalent Removing multi-function TR switch - Check whether a coded radio is installed. If so, obtain anti-theft coding. - Switch ignition off and disconnect battery Ground strap. - Install battery. - Remove battery carrier. - Shift selector lever into "P" position. - Remove nut -arrow-. - Pull lever -1- off selector shaft. - Pull off multi-function switch connector - Remove multi-function TR switch (F125) Installing and adjusting multi-function TR switch Page 5958 Install in reverse order of removal. Note all tightening torques specified in removal procedure. Page 3890 - Refer to item -15- under "Ignition System", See: Ignition System/Service and Repair 8 - Intake manifold upper section Removing and installing: 9 - 81-pin harness connector Only disconnect or connect with ignition switched off - Release to disconnect 10 - Motronic Engine Control Module (ECM) -J220-* Located in plenum chamber 11 - 40-pin harness connector Only disconnect or connect with ignition switched off 12 - Throttle valve control module - J338- No cable disc for accelerator cable as this is an electronic accelerator system - Heated by coolant 13 - Positive Crankshaft Ventilation (PCV) heating element -N79- For crankcase breather 14 - Intake hose 15 - O-ring Always replace 16 - 10 Nm (7 ft lb) 17 - Camshaft Position (CMP) sensor -G40- Refer to item 2 under "Ignition System", See: Ignition System/Service and Repair 18 - Protective housing For Secondary Air Injection (AIR) pump relay -J29919 - Mass Air Flow (MAF) sensor -G70-* with Intake Air Temperature (IAT) sensor - G4220 - Air cleaner 21 - Ignition coil -N152- With ignition cable identification; do not interchange - Refer to item 7 under "Ignition System", See: Ignition System/Service and Repair 22 - Fuel pressure regulator 23 - Vacuum positioning element For intake manifold changeover 24 - Retaining clip - Make sure it is seated securely 25 - O-ring Replace if damaged 26 - Engine Coolant Temperature (ECT) sensor -G62- Blue - For Engine Control Module (ECM) - With Engine Coolant Temperature (ECT) sensor -G2- If necessary, release pressure in cooling system before removing 27 - Engine speed (RPM) sensor -G2828 - Knock Sensor (KS) 2 -G66- Located on cylinder block, intake side - Refer to item 11 under "Ignition System", See: Ignition System/Service and Repair 29 - Secondary Air Injection (AIR) solenoid valve -N112-*/** Secondary air system 30 - Intake Manifold Tuning (IMT) valve -N156- For intake manifold change-over 31 - Secondary Injection Air (AIR) pump motor -V101- Secondary air system 32 - Fuel injectors - N30- through -N33-, -N83-, - N84- Page 2491 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Page 3489 - Reduced Transmission life. Page 257 Owner Letter Page 6581 Ambient Temperature Sensor / Switch HVAC: Locations Fresh Air Intake Duct Temperature Sensor G89 - Fresh air intake duct temperature sensor Page 4999 Fluid - M/T: Testing and Inspection 5 Speed Manual 02J Gear oil, checking Gear oil specification. Refer to Specifications Remove insulation tray below engine/transmission, if fitted. Fill Plug Location 5 Speed Manual 02J - Remove plug (arrow) to check oil The oil level is correct when the transmission is full to the lower edge of the filler hole. - Install plug (arrow). Adding Transmission Oil - Remove plug (arrow). - Top up oil to lower edge of filler hole. - Install plug (arrow). - Start engine, engage gear and allow transmission to turn for approx. 2 minutes. - Switch off engine and remove plug (arrow). - Top up oil to lower edge of filler hole again. - Install plug (arrow). Page 4432 Number in frame indicates track where the wire/circuit is continued. For example, the reference in this diagram is to track 164, which is on another diagram. In the other diagram showing track 164, the number in the frame for the same wire/circuit will change to the number 2, as that is the track number for where the wire/circuit came from on this diagram. 3 - Relay Panel - Indicated by grey area. 4 - Diagram of threaded pin on relay panel White circle shows a detachable connection. 5 - Fuse designation Use legend at bottom of page to identify the fuse code. 6 - Arrow Indicates wiring circuit is continued on the previous and/or next diagram. 7 - Wire connection designation in wiring harness Location of wire connections are indicated in the legend. 8 - Terminal designation Designation which appears on actual component and/or terminal number of a multi-point connector. For example: J226/8 = PNP Relay/terminal #8. 9 - Ground connection 10 - Component designation Use legend at bottom of page to identify the component. 11 - Component symbols 12 - Wire cross-section size (in mm sq.) and wire colors 13 - Component symbol with open drawing side Indicated component is continued on another wiring diagram. 14 - Internal connections (thin lines) These connections are not wires. Internal connections are current carrying and are listed to allow tracing of current flow inside components and wiring harness. 15 - Reference of continuation of wire to component For example: D/50b = Ignition/Starter Switch/terminal 50b. 16 - Relay panel connectors Shows wiring of multi-point or single connectors on relay panel. 17 - Reference of internal connection continuation Letters indicate where connection continues on the previous and/or next diagram. 18 - Relay location number Indicates the physical location of the relay (by position number) on the relay panel. (For an actual relay panel image/view, see the component location for the relay in question.) 19 - Legend The legend contains the explanations for all of the designation codes used within the diagram. In all wiring diagrams the same component designation (code) is used for a particular component. For example, always "A" for the battery. 20 - Power/Ground Distribution Circuit Identification Following are the most common numbered/lettered circuits: Terminal (circuit) 1 Ignition distributor low voltage (typically used as an Engine Speed (RPM) signal for the tachometer) Terminal (circuit) 15 Switch Battery Positive Voltage (B+) from ignition/starter switch Terminal (circuit) 30 Battery Positive voltage (B+), hot at all times Description and Operation Solar Sensor: Description and Operation Sunlight photo sensor -G107- Function: Controls temperature flap and fresh air blower speed depending on light intensity - In event of failure: Climatronic Control Module -J255- assumes fixed value Crash Sensor For Side Airbag, Driver Side Impact Sensor: Locations Crash Sensor For Side Airbag, Driver Side G179 - Crash sensor for side airbag, driver's side Spark Plug Pliers - AST Tool # H 1849 Spark Plug: Tools and Equipment Spark Plug Pliers - AST Tool # H 1849 Spark Plug Pliers AST tool# H 1849 Used for the R and R of spark plug connectors and specifically for those with anti-heat terminals. These Pliers are applicable to Mercedes models 190 E and 300 E, and VW/Audi. - Spark Plug Pliers - Applicable to Mercedes, VW and Audi - Steel Construction and Easy-Grip Handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Description and Operation Coolant Temperature Sensor / Switch HVAC: Description and Operation A/C cut-out thermal switch -F163- (Item # 9 in image) - Switches off A/C clutch -N25- at excessively high coolant temperatures. - Off at 119 °C (246 °F) - On at 112 °C (234 °F). Page 4317 Part 1 Page 2237 Timing Chain: Service and Repair Valve Timing, Setting Special tools, equipment, test and inspection devices; required accessories 3268 Camshaft ruler - 3406 Counter-hold - T10029 Spark plug connector tool - VAG 1331 torque wrench (5 - 50 Nm) - VAG 1332 torque wrench (40 - 200 Nm) Procedure With engine removed Install roller chain and chain tensioner with tension bar: Page 2893 Terminal (circuit) 31 Ground (GND) Terminal (circuit) 50 Starter control; switched B+ from ignition/starter switch Terminal (circuit) 56 Switched headlight B+ from light switch Terminal (circuit) 58 Switched parking light, taillight. illumination B+ from light switch Terminal (circuit) S (SU) Key in ignition circuit; switched B+ from ignition/starter switch Terminal (circuit) X Load reduction circuit; switched B+ from load reduction relay How to Use Track Diagrams Not Available For Manufacturer's Scan Tool Variable Valve Timing Actuator: Testing and Inspection Not Available For Manufacturer's Scan Tool The manufacturer does not provide a procedure using their scan tool. Page 2039 - Disconnect connector -1- from throttle control unit -2. - Unscrew ground connection at throttle control unit (J338). - Open and close balancing reservoir sealing cover to allow pressure to escape from cooling system. - Remove coolant hoses -1- and -2 from throttle control unit and plug hose ends. - Unclip fuel lines at cylinder head cover. - Disconnect vacuum connectors arrows-. - Unclip secondary air pump inlet line and all other lines out of brackets at top half of intake manifold. - Unscrew dipstick duct at top half of intake manifold. - Now unscrew two intake manifold support screws. - Remove vacuum hose at intake manifold switching vacuum actuator. Engine Controls - DTC's P0604/P0605/P0606 in Memory Engine Control Module: All Technical Service Bulletins Engine Controls - DTC's P0604/P0605/P0606 in Memory 01 07 24 Feb. 23, 2007 2010582 01 07 24, dated Feb. 23, 2007 supersedes Technical Bulletin Group 01 number 04-18 dated Aug. 26, 2004 due to inclusion in ElsaWeb. Vehicle Information Condition DTC P0604 (16988), P0605 (16989), P0606 (16990) Stored in DTC Memory Technical Background The above DTCs may also be stored due to a low battery condition. Production Solution N/A information only Service ^ Do not automatically replace the ECM for this condition. First, perform the following: ^ Verify that battery voltage and condition are OK (charge and load test as necessary). If battery voltage is low: ^ Correct reason for low battery voltage Tip: Battery voltage must be substantiated by a Midtronics MCR340V printout. The printout must be attached to the repair order. If the ECM is requested by the Warranty Test Center, a copy of the Midtronics Tester printout must be sent with the ECM along with all other supporting documentation.

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