Volkswagen Golf 1999 Service Manual
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Volkswagen Golf 1999 Service Manual

1.8 l turbo, 1.9 l tdi and pdi diesel. 2.0l gasoline, 2.8l vr6
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Summary of Contents for Volkswagen Golf 1999

  • Page 2 Bentley Publishers - eBahn® - Select a Vehicle Página 1 de 1 V o l k s w a g e n A u d i B M W Golf, GTI, Jetta 1999- 2004, Jetta Wagon 2001-2004, Subscription expires 2005 Feb 13 Golf, GTI, Jetta 1993-1999,...
  • Page 3 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF Página 1 de 1 Select a topic 00 - General, Technical data 10 - Engine - Assembly 13 - Engine - Crankshaft, Cylinder block 15 - Engine - Cylinder head, Valvetrain 17 - Engine - Lubrication 19 - Engine - Cooling system 20 - Fuel Supply...
  • Page 4 Technical data Página 1 de 3 00-1 Technical data Engine number The engine number (engine code and serial number) are located next to the vibration damper on the cylinder block. The engine number consists of up to nine characters (alphanumeric). The first part (maximal 3 characters) makes up the engine code and the second part (6 characters), the serial...
  • Page 5 Technical data Página 2 de 3 00-2 Engine data Engine code Manufactured 08.01 Cylinder application Cylinder angle 15.0 Capacity ltr. Output kW at rpm 147/6200 Torque Nm at rpm 265/3200 Bore diameter mm 81.0 Stroke 90.3 Compression ratio 10.75 min. 98 unleaded System designation Motronic ME7.1.1...
  • Page 6 Technical data Página 3 de 3 00-3 Engine code Exhaust emissions level On Board Diagnostic (OBD) OBD II Knock regulation 2 knock sensors Oxygen sensor control 2 sensors Catalytic converter Exhaust gas recirculation Charging Secondary air system Electronic power control (EPC) Variable intake manifold Variable valve timing LEV = Low Emission Vehicles (exhaust emissions max.
  • Page 7 Engine, removing and installing Página 1 de 22 10-1 Engine, removing installing Special tools and equipment 3033 Lifting tackle 3269 Engine bracket 3395 Engine bracket VW 313 Support clamp VW 540/1 B Supplementary T10095 Puller http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 8 Engine, removing and installing Página 2 de 22 10-2 VAG 1202 A Workshop crane VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 Nm) VAG 1332 Torque wrench (40...200 VAG 1383 A Engine/transmission jack VAS 5024 Assembly tool for spring-type clips VAS 5085 Step ladder G 000 100 Grease...
  • Page 9 Engine, removing and installing Página 3 de 22 10-3 Notes on removing The engine is removed downward together with the transmission. CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g.
  • Page 10 Engine, removing and installing Página 4 de 22 10-4 - With ignition switched off disconnect battery Ground strap. - Disconnect connectors from ignition coils 1...6. Note: Mark connector and component before disconnecting. - Remove ignition coils with final out stage for cylinders 1...6 using puller T10095.
  • Page 11 Engine, removing and installing Página 5 de 22 10-5 WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection. - Seal lines to avoid contamination of fuel system.
  • Page 12 Engine, removing and installing Página 6 de 22 10-6 - Remove intake manifold Page 15-16 Removing and installing cylinder head cover. Note: Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth. - Remove ribbed belt Page 13-19 - Remove power steering pump on compact bracket and place to side;...
  • Page 13 Engine, removing and installing Página 7 de 22 10-7 - Separate hydraulic line to slave cylinder for hydraulic clutch: Repair Manual, 5 & 6 Spd. Manual Transmission 02M, Repair Group 30 Models with an automatic transmission - Remove gate selector lever cable from transmission: Repair Manual, 5 Spd.
  • Page 14 Engine, removing and installing Página 8 de 22 10-8 Camshaft adjustment valve 1 (exhaust) - N318-, Camshaft Position (CMP) sensor -G40-, Camshaft Position (CMP) sensor 2 -G163- Injectors (-N30- to -N33-, -N83- and -N84- Engine speed (RPM) sensor -G28-, Knock Sensor (KS) 1 -G61-, Knock Sensor (KS) 2 -G66-, Installation locations: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 15 Engine, removing and installing Página 9 de 22 10-9 - Pull all coolant hoses off to engine using assembly tool for spring-type clamps VAS 5024. - Removing drive shafts: Repair Manual, Suspension, Wheels, Steering, Repair Group 40 - Remove pendulum support: Repair Manual, Suspension, Wheels, Steering, Repair Group 40 - Remove front exhaust pipe with catalytic...
  • Page 16 Engine, removing and installing Página 10 de 22 10-10 - Install engine bracket 3395 to cylinder block and tighten securing nuts -1- to 40 Nm. - Lift engine and transmission slightly using engine/transmission jack VAG 1383 A. - Unbolt engine side of assembly mounting from engine bracket at top (arrows).
  • Page 17 Engine, removing and installing Página 11 de 22 10-11 - Unbolt transmission side of assembly mounting from top of transmission carrier (arrows). Note: Use ladder VAS 5085 to remove securing bolts. - Carefully lower engine with transmission. Note: Engine with transmission must be guided carefully, when lowering, to prevent damage to bodywork.
  • Page 18 Engine, removing and installing Página 12 de 22 10-12 Securing engine to assembly stand Note: When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 and supplementary set 540/1 B. Work sequence - Remove transmission.
  • Page 19 Engine, removing and installing Página 13 de 22 10-13 Notes on installation Install in reverse sequence ; note the following points: - Check whether dowel sleeves for centering engine/transmission are installed in cylinder block and install if necessary. Models with a manual transmission - Check clutch and clutch operating mechanism and install: Repair Manual, 5 &...
  • Page 20 Engine, removing and installing Página 14 de 22 10-14 Continuation for all vehicles - When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator. - Align engine and transmission mountings Page 10-18 Note: Torque settings for assembly mountings Page 10-21 - Install compact bracket and alternator:...
  • Page 21 Engine, removing and installing Página 15 de 22 10-15 Models with a manual transmission - Install gear selector mechanism: Repair Manual, 5 & 6 Spd. Manual Transmission 02M, Repair Group 34 - If necessary adjust gear selector cables: Repair Manual, 5 & 6 Spd. Manual Transmission 02M, Repair Group 34 - Install hydraulic line to hydraulic clutch slave cylinder:...
  • Page 22 Engine, removing and installing Página 16 de 22 10-16 Continuation for all vehicles - Install power steering pump: Repair Manual, Suspension, Wheels, Steering, Repair Group 48 - Install intake manifold Page 15-16 , Removing and installing cylinder head cover. - Install air cleaner with intake hose: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF, Repair Group - Install battery and battery retainer.
  • Page 23 Engine, removing and installing Página 17 de 22 10-17 - Adapt (match) engine control module to throttle valve control module: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF, Repair Group - Perform work sequence "Procedure after interrupting voltage supply": Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF, Repair Group - Read readiness code:...

  • Page 24: Página 18 De

    Engine, removing and installing Página 18 de 22 10-18 Aligning engine and transmission mountings Special tools and equipment Support device 10-222 A with legs 10-222 A/1 and adapter 10- 222 A/3 WARNING! Before loosening bolts, secure assembly using support device 10-222A.
  • Page 25 Engine, removing and installing Página 19 de 22 10-19 Engine mounting a = 14.0 mm b = at least 10.0 mm Both bolt heads -1- must be flush with edge -c-. Transmission assembly mounting Edges -a- and -b- must be parallel to each other.
  • Page 26 Engine, removing and installing Página 20 de 22 10-20 Torque settings Bolted connections Torque setting Bolts, nuts 10 Nm 15 Nm 25 Nm 40 Nm 60 Nm Deviations Connecting bolts, engine to 60 Nm transmission Connecting bolts, engine to 80 Nm transmission Starter to engine and transmission 45 Nm...
  • Page 27 Engine, removing and installing Página 21 de 22 10-21 Assembly mounting Torque settings Engine mounting Mounting to 40 Nm + body 90 ( turn) Support to 20 Nm + mounting at 90 ( body turn) Mounting to 100 Nm engine bracket Replace bolts Transmission assembly mounting Mounting to...
  • Page 28 Engine, removing and installing Página 22 de 22 10-22 Additional information and assembly work on models with air conditioning WARNING! The air conditioning refrigerant circuit must not be opened. Note: The refrigerant circuit must only be opened in workshops with trained personnel and the necessary range of tools and workshop equipment.
  • Page 29 Engine, disassembling and assembling Página 1 de 31 13-1 Engine, disassembling assembling Note: When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 and supplementary set 540/1 B. If when repairing an engine, metal shavings or large amounts of small...
  • Page 30 Engine, disassembling and assembling Página 2 de 31 13-2 Page 13-3 Page 13- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 31 Engine, disassembling and assembling Página 3 de 31 13-3 Part I 1 - Control housing Lubricate contact surfaces of oil seal when installing Removing installing Page 15-69 Removing installing camshaft Disassembling assembling Page 15-64 Fig. 6 Check screen of control housing for soiling before...
  • Page 32 Engine, disassembling and assembling Página 4 de 31 position) Fig. 1 Installing Page 15-39 Adjusting valve timing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 33 Engine, disassembling and assembling Página 5 de 31 13-4 4 - Exhaust camshaft timing adjuster Marking: Turn engine over only when camshaft timing adjuster installed Check camshaft timing adjustment Page 15-82 Installing Page 15-39 Adjusting valve timing Intermediate shaft 6 - Thrust washer 7 - 8 Nm Insert with...
  • Page 34 Engine, disassembling and assembling Página 6 de 31 9 - Mounting stud, 10 tensioning plate item http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...

  • Page 35: Página 7 De

    Engine, disassembling and assembling Página 7 de 31 13-5 Chain tensioner, 40 Nm camshaft roller chain item 3 Turn engine over only when chain tensioner installed 11 - Seal Replace damaged leaking 12 - Chain sprocket roller chain item Installing Page 15-39 Adjusting...
  • Page 36 Engine, disassembling and assembling Página 8 de 31 15-39 Adjusting valve timing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 37 Engine, disassembling and assembling Página 9 de 31 13-6 60 Nm plus additional turn (90 ) further Replace counter support T10069 to loosen tighten Page 15-39 Adjusting valve timing Chain tensioner with tensioning rail roller chain item Before installation release the locking device in the chain...
  • Page 38 Engine, disassembling and assembling Página 10 de 31 Turn engine over only when chain tensioner installed 16 - Drive sprocket Integral part of crankshaft Ground down tooth aligned with main bearing joint = TDC cyl. Page 15- Adjusting valve timing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 39 Engine, disassembling and assembling Página 11 de 31 13-7 17 - Roller chain Mark direction of rotation before removing (installation position) Fig. 1 Installing Page 15-39 Adjusting valve timing 18 - Guide rail roller chain item Remove install together with roller chain Page 15-...
  • Page 40 Engine, disassembling and assembling Página 12 de 31 guide rail item 21 - 23 Nm guide rail item http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 41 Engine, disassembling and assembling Página 13 de 31 13-8 Intake camshaft timing adjuster Marking: Turn engine over only when camshaft timing adjuster installed Check camshaft timing adjustment Page 15-82 Installing Page 15-39 Adjusting valve timing 60 Nm plus additional turn (90 ) further Replace...
  • Page 42 Engine, disassembling and assembling Página 14 de 31 install, use a 32 mm open spanner camshaft to counter support Page 15-69 Removing installing camshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 43 Engine, disassembling and assembling Página 15 de 31 13-9 24 - Guide rail camshaft roller chain item 3 Camshaft adjustment valve 2 (exhaust) - N318- Check camshaft timing adjustment Page 15-82 Mark connector component before pulling connector Checking activation: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 44 Engine, disassembling and assembling Página 16 de 31 timing adjustment Page 15-82 Mark connector component before pulling connector Checking activation: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 45 Engine, disassembling and assembling Página 17 de 31 13-10 27 - Guide rail camshaft roller chain item 3 Clipped into control housing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 46 Engine, disassembling and assembling Página 18 de 31 13-11 Fig. 1 Marking roller chains - Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation). Note: Do not mark chain with a punched mark, notch or similar! http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 47 Engine, disassembling and assembling Página 19 de 31 13-12 Part II 1 - 45 Nm 2 - Engine bracket 3 - 8 Nm Secured to intake manifold 4 - Dipstick The oil level must exceed max. mark! Markings Page 17-8 Fig.
  • Page 48 Engine, disassembling and assembling Página 20 de 31 13-13 6 - Cylinder block Removing installing sealing flange and dual- mass flywheel Page 13-22 Removing installing crankshaft Page 13-34 Disassembling assembling piston and conrod Page 13-39 7 - Knock Sensor (KS) 1 - G61- 3-pin Installation...
  • Page 49 Engine, disassembling and assembling Página 21 de 31 corrosion, dirt and grease. Checking: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 01 8 - 20 Nm Torque setting influences function of knock sensor http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 50 Engine, disassembling and assembling Página 22 de 31 13-14 9 - 10 Nm 10 - Oil pump drive cover 11 - O-ring Replace Lubricate before installing 12 - Oil pump drive 13 - Oil non- return valve, 5 Observe installation position Clean if badly...
  • Page 51 Engine, disassembling and assembling Página 23 de 31 13-15 18 - Oil pump Disassembling assembling Page 17-12 Coat oil pressure pipe at cylinder block and oil pump housing with sealing compound AMV 188 001 02 19 - 23 Nm 20 - 8 Nm Insert with locking compound...
  • Page 52 Engine, disassembling and assembling Página 24 de 31 13-16 24 - Oil filter housing See note Page 13-1 Disassembling assembling Page 17-9 Coolant hose connection diagram Page 19- 25 - Vibration damper Removing installing ribbed belt Page 13- 26 - 100 Nm plus additional turn...
  • Page 53 Engine, disassembling and assembling Página 25 de 31 1601 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 54 Engine, disassembling and assembling Página 26 de 31 13-17 27 - Knock Sensor (KS) 2 - G66- 2-pin Installation location: Between cyl. 4 and cyl. 6 contact surfaces between knock sensor cylinder block must be free of corrosion, dirt and grease.
  • Page 55 Engine, disassembling and assembling Página 27 de 31 Engine Code (s): BDF, Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 56 Engine, disassembling and assembling Página 28 de 31 13-18 Fig. 1 To loosen and tighten securing bolt, hold vibration damper with counter support T10069 Note: Vibration damper securing bolt must be replaced. Tighten securing bolt with torque wrench VAG 1601. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 57 Engine, disassembling and assembling Página 29 de 31 13-19 Ribbed belt, removing and installing Special tools and equipment VAS 5024 Assembly tool for spring-type clips Hex bolt M8x45 Removing ribbed belt Note: Mark ribbed belt direction of rotation before removing. Make sure ribbed belt is seated correctly in pelt pulley when installing.
  • Page 58 Engine, disassembling and assembling Página 30 de 31 13-20 - Pull off return hose -1- (with blue marking) and collect fuel that may leak out with a cloth. - Seal lines to avoid contamination of fuel system. - Observe rules for cleanliness Page 20-14 - Removing right hand insulation tray:...
  • Page 59 Engine, disassembling and assembling Página 31 de 31 13-21 Installing ribbed belt - Install in reverse order. Note: Make sure, before installing ribbed belt, that all ancillaries (alternator, air conditioning compressor, power steering pump) are secured tightly. When installing the ribbed belt observe belt direction of rotation and that the belt is seated correctly in the belt pulleys.
  • Page 60 Sealing flanges and dual-mass flywheel, removing and installing Página 1 de 14 13-22 Sealing flanges and dual- mass flywheel, removing installing Note: Servicing clutch: Repair Manual, 5 & 6 Spd. Manual Transmission 02M, Repair Group 30 When working on the engine it should be secured to assembly...
  • Page 61 Sealing flanges and dual-mass flywheel, removing and installing Página 2 de 14 13-23 1 - 100 Nm plus additional turn (90 ) further Replace counter support T10069 to loosen tighten Page 13- Replacing crankshaft oil seal - vibration pulley end Tighten using torque...
  • Page 62 Sealing flanges and dual-mass flywheel, removing and installing Página 3 de 14 coil spring Do not additionally lubricate the oil seal sealing lip Before installing, remove oil remains from crankshaft journal with a clean cloth Replacing Page 13-27 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 63 Sealing flanges and dual-mass flywheel, removing and installing Página 4 de 14 13-24 5 - Sealing flange Coat sealing surfaces with sealing compound AMV 188 001 02 6 - Cylinder block Removing installing crankshaft Page 13-34 Disassembling assembling piston and connecting Page 13-39...
  • Page 64 Sealing flanges and dual-mass flywheel, removing and installing Página 5 de 14 13-25 8 - Seal PTFE seal version Marking: With no inner coil spring Do not additionally lubricate the oil seal sealing lip Remove with extractor hook 2086 Before installing, remove oil remains...
  • Page 65 Sealing flanges and dual-mass flywheel, removing and installing Página 6 de 14 drive plate Page 13- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 66 Sealing flanges and dual-mass flywheel, removing and installing Página 7 de 14 13-26 60 Nm plus additional turn (90 ) further Replace counter support T10069 loosen tighten 11 - 23 Nm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 67 Sealing flanges and dual-mass flywheel, removing and installing Página 8 de 14 13-27 Crankshaft oil seal (vibration damper end), replacing Special tools equipment 3203 Oil seal extractor 3266 Sleeve T10069 Counter support T10053/1 Guide sleeve VAG 1601 Torque wrench (150...800 VAG 1332 Torque wrench...
  • Page 68 Sealing flanges and dual-mass flywheel, removing and installing Página 9 de 14 13-28 Removing - Remove ribbed belt Page 13- - Remove vibration damper. To do this, hold vibration damper with counter support T10069. - Unscrew inner part of oil seal extractor 3203 three turns (approx.
  • Page 69 Sealing flanges and dual-mass flywheel, removing and installing Página 10 de 14 13-29 Installing Note: A PTFE seal (Teflon) -2- is gradually being introduced instead of the inner coil spring type seal-1-. This has a wider sealing lip. PTFE seals are fitted free of oil and grease.
  • Page 70 Sealing flanges and dual-mass flywheel, removing and installing Página 11 de 14 13-30 - Press seal against limit stop using press sleeve from 3266. Use old mounting bolt for vibration damper for this purpose. - Install vibration damper and lock it with counter support T10069.
  • Page 71 Sealing flanges and dual-mass flywheel, removing and installing Página 12 de 14 13-31 Drive plate, removing and installing Special tools and equipment T10069 Counter support VAG 1332 Torque wrench (40...200 Nm) Depth gauge Straight edge http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 72 Sealing flanges and dual-mass flywheel, removing and installing Página 13 de 14 13-32 Removing - Remove drive plate. To do this, hold vibration damper with counter support T10069. - Loosen drive plate securing bolts using cross-over sequence and remove them. - Remove drive plate.
  • Page 73 Sealing flanges and dual-mass flywheel, removing and installing Página 14 de 14 13-33 If the specification is not obtained: - Remove drive plate again and install appropriate shim -1-. Note: Only one shim of the appropriate thickness may be used to compensate.
  • Page 74 Crankshaft, removing and installing Página 1 de 9 13-34 Crankshaft, removing installing Note: When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 supplementary set 540/1 B. Before removing the crankshaft, ensure that a suitable place...
  • Page 75 Crankshaft, removing and installing Página 2 de 9 Bearing cap 5 with recesses for thrust washers Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 76 Crankshaft, removing and installing Página 3 de 9 13-35 2 - 30 Nm plus additional turn (180 ) further Replace Turning 2 x 90 further is permitted 3 - Bearing shells 1...7 Observe note before removing Page 13-34 bearing without groove cylinder block...
  • Page 77 Crankshaft, removing and installing Página 4 de 9 Check locating point http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 78 Crankshaft, removing and installing Página 5 de 9 13-36 5 - Crankshaft Observe note before removing Page 13-34 Axial clearance new: 0.07...0.24 mm, Wear limit: 0.30 Check radial clearance with Plastigage, New: 0.02...0.06 mm, Wear limit: 0.10 Do not turn crankshaft when checking...
  • Page 79 Crankshaft, removing and installing Página 6 de 9 sensor - G28- Replace Installing Fig. 1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 80 Crankshaft, removing and installing Página 7 de 9 13-37 7 - 10 Nm plus additional turn (90 ) further Replace Observe sequence when tightening Fig. 1 8 - Thrust bearing bearing cap 5 Check locating point 9 - Oil spray crankshaft bearings 2...7...
  • Page 81 Crankshaft, removing and installing Página 8 de 9 Page 13-1 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 82 Crankshaft, removing and installing Página 9 de 9 13-38 Fig. 1 Installing sensor wheel to crankshaft Special tools and equipment VAG 1331 Torque wrench (5...50 D 000 600 A2 Locking compound Work sequence Make sure crankshaft/sensor wheel contact surfaces are free of oil and grease.

  • Page 83: Table Of Contents

    Piston and connecting rod, disassembling and assembling Página 1 de 13 13-39 Piston and connecting rod, disassembling assembling 1 - Piston rings Offset gaps by Use piston ring pliers to remove and install "TOP" faces towards piston crown Checking ring Fig.
  • Page 84 Piston and connecting rod, disassembling and assembling Página 2 de 13 3 - Snap ring http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 85 Piston and connecting rod, disassembling and assembling Página 3 de 13 13-40 4 - Conrod Only replace as a Mark position cylinder Installation position: Marks -A- must be aligned above one another 5 - Bearing shell Observe installation position Do not interchange used bearing...
  • Page 86 Piston and connecting rod, disassembling and assembling Página 4 de 13 Plastigage: New: 0.02...0.07 mm, Wear limit: 0.10 mm. Do not turn crankshaft when checking radial clearance http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 87 Piston and connecting rod, disassembling and assembling Página 5 de 13 13-41 6 - Conrod bearing Mark position cylinder Installation position: Marks -A- must be aligned above one another 7 - 30 Nm plus additional turn (90 ) further Replace thread contact surface...
  • Page 88 Piston and connecting rod, disassembling and assembling Página 6 de 13 installing crankshaft Page 13-34 Piston and cylinder dimensions Page 13-48 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 89 Piston and connecting rod, disassembling and assembling Página 7 de 13 13-42 9 - Piston difficult remove, heat piston to 60 Remove install with drift 222a http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 90 Piston and connecting rod, disassembling and assembling Página 8 de 13 13-43 Fig. 1 Checking piston ring gap Special tools and equipment Feeler gauge Test sequence - Push ring squarely from above down to approx. 15 mm from bottom end of cylinder.
  • Page 91 Piston and connecting rod, disassembling and assembling Página 9 de 13 13-44 Fig. 2 Checking ring to groove clearance Special tools and equipment Feeler gauge Test sequence - Clean ring groove before checking. Piston ring Ring to groove clearance Wear limit Compression mm 0.04...0.08...
  • Page 92 Piston and connecting rod, disassembling and assembling Página 10 de 13 13-45 Fig. 3 Checking piston Special tools and equipment External micrometer 75...100 mm Test sequence - Take measurement approx. 6 mm from lower edge of piston skirt and offset 90 to piston axis. Deviation from nominal dimension: max.
  • Page 93 Piston and connecting rod, disassembling and assembling Página 11 de 13 13-46 Fig. 4 Checking cylinder bores Special tools and equipment Internal dial gauge 50...100 mm Test sequence - Measure bores at 3 locations in both directions -A- across engine and -B- in line with crankshaft.
  • Page 94 Piston and connecting rod, disassembling and assembling Página 12 de 13 13-47 Fig. 5 Installing pistons with piston installation tool (funnel) 3278 Special tools and equipment 3278 Funnel Note: If a new installation tool (funnel) is used to install the pistons, first pass piston with oiled piston rings through the funnel twice and remove the resulting metal shavings if...
  • Page 95 Piston and connecting rod, disassembling and assembling Página 13 de 13 13-48 Piston and cylinder dimensions Honing Piston Cylinder dimension diameter bore diameter Basic 80.965 81.010 dimension 1st oversize 81.465 81.510 2nd oversize 81.965 82.010 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...

  • Page 96: Cylinder Head

    Cylinder head, servicing Página 1 de 58 15-1 Cylinder head, servicing Note: If an exchange cylinder head is installed, all contact surfaces between bearing elements, roller rocker fingers and running surfaces of camshaft must be oiled before installing cylinder head cover. The plastic protectors installed to...
  • Page 97 Cylinder head, servicing Página 2 de 58 15-2 Removing and installing intake manifold Page 15-16 Removing and installing cylinder head. Disassembling assembling intake manifold: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 24 Removing and installing cover...
  • Page 98 Cylinder head, servicing Página 3 de 58 damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 99 Cylinder head, servicing Página 4 de 58 15-3 5 - O-ring Replace damaged Lubricate before installing ignition coils with final output stage 6 - Sealing Replace seal if damaged 7 - Boot Replace damaged 8 - Cylinder head cover Replace damaged Removing installing...
  • Page 100 Cylinder head, servicing Página 5 de 58 15-4 11 - Camshaft roller chain Mark direction of rotation. before removing (installation position) Page 13- , Fig. 1 Installing Page 15-39 Adjusting valve timing 12 - Combi- valve Removing installing Page 26-24 Removing installing parts of...
  • Page 101 Cylinder head, servicing Página 6 de 58 timing adjustment Page 15-82 Mark connector component before disconnecting Checking activation: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 01; Output Diagnostic Test Mode http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 102 Cylinder head, servicing Página 7 de 58 15-5 14 - Camshaft adjustment valve 1 (exhaust) - N318- Check camshaft timing adjustment Page 15-82 Mark connector component before disconnecting Checking activation: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 01;...
  • Page 103 Cylinder head, servicing Página 8 de 58 install, use a 32 mm open wrench camshaft to counter support Page 15-69 Removing installing camshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 104 Cylinder head, servicing Página 9 de 58 15-6 Exhaust camshaft timing adjuster Marking: Turn engine over only when camshaft timing adjuster installed Check camshaft timing adjustment Page 15-82 Installing Page 15-39 Adjusting valve timing 17 - Slide rail camshaft roller chain item - 11 Clipped...
  • Page 105 Cylinder head, servicing Página 10 de 58 Turn engine over only when camshaft timing adjuster installed Check camshaft timing adjustment Page 15-82 Installing Page 15-39 Adjusting valve timing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 106 Cylinder head, servicing Página 11 de 58 15-7 19 - Unions For air shrouding injectors 20 - Cylinder head gasket Metal gasket Replace Preparing cylinder head gasket for installation Fig. 2 After replacement replace entire coolant 21 - Cylinder head Check distortion Fig.
  • Page 107 Cylinder head, servicing Página 12 de 58 belt Removing installing ribbed belt Page 13- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 108 Cylinder head, servicing Página 13 de 58 15-8 23 - Cylinder head bolt Replace Observe installation instructions sequence when loosening tightening Page 15-25 Removing installing cylinder head 24 - Cylinder head cover gasket Replace damaged leaking Observe installation position http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 109 Cylinder head, servicing Página 14 de 58 15-9 Fig. 1 Checking cylinder head for distortion Special tools and equipment Straightedge Feeler gauge Max. permissible distortion: 0.05 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 110 Cylinder head, servicing Página 15 de 58 15-10 Fig. 2 Preparing cylinder head gasket for installation Special tools and equipment AMV 174 004 01 Sealing compound AMV 188 001 02 Sealing compound Work sequence - Clean old sealing compound from 3 mm holes in cylinder head gasket (arrows).
  • Page 111 Cylinder head, servicing Página 16 de 58 15-11 Cover, removing and installing 1 - Cable guide coolant hoses wiring harness Coolant hose connection diagram Page 19- 2 - 8 Nm 3 - Camshaft Position (CMP) sensor 2- G163- exhaust camshaft Mark connector component...
  • Page 112 Cylinder head, servicing Página 17 de 58 camshaft roller chain Page 15- , item - 11 - Turn engine over only when chain tensioner installed http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 113 Cylinder head, servicing Página 18 de 58 15-12 5 - Seal Replace damaged leaking 6 - Cover Can be removed installed with cylinder head fitted Coat sealing surfaces with sealing compound AMV 188 001 02 With O- ring for sealing passage, item - 14 If only...
  • Page 114 Cylinder head, servicing Página 19 de 58 tighten securing bolts (item - 9 -) to 23 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...

  • Page 115: Disassembling And Assembling

    Cylinder head, servicing Página 20 de 58 15-13 8 - Seal Valve -1- camshaft adjustment -N205-, Page 15- , item - 13 - and Camshaft adjustment valve 1 (exhaust) - N318-, Page 15- , item - 14 - Replace damaged or leaking Installing Fig.
  • Page 116 Cylinder head, servicing Página 21 de 58 15-14 13 - Camshaft Position (CMP) sensor - G40- intake camshaft Mark connector component before disconnecting Checking: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 01 14 - O-ring For oil channel...
  • Page 117 Cylinder head, servicing Página 22 de 58 15-15 Fig. 1 Installing seals for cover Special tools and equipment 3378 Puller sleeve 3253/6 Puller sleeve from fitting device 3253 Installing Note: Do not oil seal. - Position seal in cover -1- using puller sleeve 3378 and pull in flush using puller sleeve 3253/6 from fitting device 3253.
  • Page 118 Cylinder head, servicing Página 23 de 58 15-16 Cylinder head cover, removing installing Special tools equipment T10095 Puller V.A.G 1331 Torque wrench (5...50 VAS 5024 Assembly tool for spring- type clips Cable tie http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 119 Cylinder head, servicing Página 24 de 58 15-17 Removing CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
  • Page 120 Cylinder head, servicing Página 25 de 58 15-18 - Disconnect connectors from ignition coils 1...6. Note: Mark connector and component before disconnecting. - Unclip ignition coils wiring harness from wiring guide. - Remove ignition coils with final output stage for cylinders 1...6 using puller T10095.
  • Page 121 Cylinder head, servicing Página 26 de 58 15-19 - Disconnect 6-pin connector from throttle valve control module (arrow). - Open and close expansion tank cap to release pressure in cooling system. - Pull coolant hoses off throttle valve control module and seal hose ends.
  • Page 122 Cylinder head, servicing Página 27 de 58 15-20 - Remove retaining frame on cylinder head for fuel lines and wiring harness (arrows). - Disconnect vacuum hoses (arrows) from intake manifold. Note: Press buttons on hose couplings to do so. - Remove rearmost bolt -1- for intake manifold support.
  • Page 123 Cylinder head, servicing Página 28 de 58 15-21 - Remove Ground connection on support of combi-valve Page 26-25 , item - 9 -. - Disconnect vacuum hose from variable intake manifold change-over vacuum actuator. - Remove two lateral intake manifold support bolts.
  • Page 124 Cylinder head, servicing Página 29 de 58 15-22 - Remove intake manifold and place on a suitable surface so that vacuum actuator is not damaged. Note: Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth. - Remove cylinder head cover.
  • Page 125 Cylinder head, servicing Página 30 de 58 15-23 - Adapting engine control module to throttle valve control module: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group - Perform work sequence "Procedure after interrupting voltage supply": Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 126 Cylinder head, servicing Página 31 de 58 15-24 Torque settings Bolted connections Torque setting Cylinder head cover to cylinder 8 Nm head Intake manifold to cylinder head 13 Nm Intake manifold to support 23 Nm Dipstick guide tube to intake 8 Nm manifold http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 127 Cylinder head, servicing Página 32 de 58 15-25 Cylinder head, removing installing Special tools equipment T10068 Camshaft V.A.G 1306 Drip tray V.A.G 1331 Torque wrench (5...50 V.A.G 1332 Torque wrench (40...200 VAS 5024 Assembly tool for spring- type clips AMV 174 004 01 Sealing compound...
  • Page 128 Cylinder head, servicing Página 33 de 58 15-26 Conditions The engine must only be warm to the touch. Removing CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original...
  • Page 129 Cylinder head, servicing Página 34 de 58 15-27 - Remove intake manifold Page 15-16 Removing and installing cylinder head cover. - Disconnect 4-pin connector (arrow) from Engine Coolant Temperature (ECT) sensor -G62 Engine Coolant Temperature sensor -G2 - Drain coolant Page 19-15 - Remove coolant thermostat housing Page 19...
  • Page 130 Cylinder head, servicing Página 35 de 58 15-28 - Remove camshaft roller chain tensioner (arrow). - Disconnect connections from following components on cover: Camshaft Position (CMP) sensor -G40- -1-, Camshaft Position (CMP) sensor 2 -G163- -2-, Valve -1- for camshaft adjustment -N205- -3-, Camshaft adjustment valve 1 (exhaust) -N318- -4-.
  • Page 131 Cylinder head, servicing Página 36 de 58 15-29 - Remove camshaft cover Page 15-11 Removing and installing camshaft. - Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation). Note: Do not mark chain with a punched mark, notch or similar! - Separate front exhaust pipe from exhaust manifold...
  • Page 132 Cylinder head, servicing Página 37 de 58 15-30 If the notch cannot be seen: - Turn crankshaft one full turn further in engine direction of rotation. Note: When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner.
  • Page 133 Cylinder head, servicing Página 38 de 58 15-31 Check setting marks of camshaft timing adjusters with marks on control housing: Marks -A and B- on camshaft timing adjusters must align with notches (arrows) on control housing -C-. Distance between tooth -1- and tooth -2- of camshaft timing adjuster must be exactly 16 rollers of camshaft roller chain.
  • Page 134 Cylinder head, servicing Página 39 de 58 15-32 - Remove guide rail securing bolts (arrow) and remove guide rail -1-. - Place camshaft roller chain to side. - Loosen socket head bolts in sequence given and then remove. Note: Use tool 3452 for Polydrive cylinder head bolts.
  • Page 135 Cylinder head, servicing Página 40 de 58 15-33 Installing - Place a clean cloth into cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston. Note: Also prevent dirt and emery cloth particles from getting into coolant.
  • Page 136 Cylinder head, servicing Página 41 de 58 15-34 Note: Only remove the new cylinder head gasket from its packing immediately before installing. Handle the new gasket with extreme care. Damage will lead to leaks. - Install new cylinder head gasket. Inscription (Part No.) must be legible.
  • Page 137 Cylinder head, servicing Página 42 de 58 15-35 - Fill 3 mm holes in cylinder head gasket with sealing compound AMV 188 001 02. Note: When the cylinder head is installed the holes in the cylinder head gasket are only half visible. - Install cylinder head, insert new cylinder head bolts and tighten by hand.
  • Page 138 Cylinder head, servicing Página 43 de 58 15-36 The rest of the assembly is basically in reverse order to the disassembling sequence. Note: Ensure that the O-ring for sealing the oil channel and the seal in the cover are installed. - Adjust valve timing Page 15-39 - Install cylinder head cover and intake manifold...
  • Page 139 Cylinder head, servicing Página 44 de 58 15-37 Valve timing, checking Special tools and equipment T10068 Camshaft bar Test sequence - Remove intake manifold and cylinder head cover Page 15- ; Removing and installing cylinder head. - Turn crankshaft over on vibration damper securing bolt in engine direction of rotation (arrow).
  • Page 140 Cylinder head, servicing Página 45 de 58 15-38 The camshaft bar T10068 must engage in both shaft grooves. If the camshaft bar will not fit: - Turn crankshaft one full turn further in engine direction of rotation. Note: If the camshaft bar cannot be installed, turn the crankshaft in engine direction of rotation until approx.
  • Page 141 Cylinder head, servicing Página 46 de 58 15-39 Valve timing, adjusting (Install timing chains) Special tools equipment T10068 Camshaft T10069 Counter support V.A.G 1331 Torque wrench (5...50 V.A.G 1332 Torque wrench (40...200 AMV 174 004 01 Sealing compound AMV 188 001 01 Sealing compound...
  • Page 142 Cylinder head, servicing Página 47 de 58 15-40 Work sequence CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
  • Page 143 Cylinder head, servicing Página 48 de 58 15-41 Install roller chain and chain tensioner with tensioning plate for intermediate shaft drive: - Adjust position of crankshaft relative to intermediate shaft. To position: Align ground-down tooth of drive chain sprocket -B- with mounting joint (TDC cyl.
  • Page 144 Cylinder head, servicing Página 49 de 58 15-42 - Tighten chain sprockets -3- and - 4- on the intermediate shaft by hand. Note: Please observe that all chain sprocket securing screws/bolts must be replaced. - Install chain tensioner on opposite side.
  • Page 145 Cylinder head, servicing Página 50 de 58 15-43 - Tighten new securing bolts of chain sprocket -3- and -4- for intermediate shaft to 60 Nm + 90 ( turn - turning further can be done in several stages). - Remove counter support T10069. - Check position of crankshaft -B- to intermediate shaft -C- or -D- once again.
  • Page 146 Cylinder head, servicing Página 51 de 58 15-44 It must be possible to insert camshaft bar T10068 into both shaft slots. Note: If the cylinder head is removed: Page 15-25 , Removing and installing cylinder head. - Place camshaft roller chain on intermediate shaft chain sprocket.
  • Page 147 Cylinder head, servicing Página 52 de 58 15-45 Note: The exhaust camshaft timing adjuster -1- can be turned in two directions. When installing, ensure that the sensor wheel -2- for the CMP sensor -G163- is turned onto limit stop in direction of (arrow). The distance between the two ground- down teeth of the intake and exhaust camshaft timing adjusters (markings...
  • Page 148 Cylinder head, servicing Página 53 de 58 15-46 Note: When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner. If the marks do not align: - Repeat timing adjustment. If the marks align: - Hold camshaft to be tightened with a 32 mm open end wrench...
  • Page 149 Cylinder head, servicing Página 54 de 58 15-47 - Replace flywheel/drive plate sealing flange Page 13-24 , item - 7 -. - Remove old sealing compound from 3 mm holes in cylinder head gasket (arrows). - Fill 3 mm holes in cylinder head gasket with sealing compound AMV 174 004 02.
  • Page 150 Cylinder head, servicing Página 55 de 58 15-48 Compression pressure, checking Special tools and equipment 3122 B Spark plug wrench T10095 Puller V.A.G 1331 Torque wrench (5...50 Nm) V.A.G 1763 Compression tester http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 151 Cylinder head, servicing Página 56 de 58 15-49 Test conditions Engine oil temperature at least 30 C The battery voltage must be at least 11.5 V. All electrical consumers, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 152 Cylinder head, servicing Página 57 de 58 15-50 - Disconnect connectors from ignition coils 1...6. Note: Mark connector and component before disconnecting. - Remove ignition coils with final output stage for cylinders 1...6 using puller T10095. - Remove spark plugs with spark plug wrench 3122 B.
  • Page 153 Cylinder head, servicing Página 58 de 58 15-51 Compression pressure values New: 10...13 bar Wear limit: 7.5 bar Permissible difference between all cylinders: 3 - Check DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group - Read readiness code: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 154 Valve gear, servicing Página 1 de 49 15-52 Valve gear, servicing 1 - 5 Nm + turn (45 ) further 2 - Exhaust camshaft bearing Before installing bearing cap 8, grease lightly the contact surface with G 052 723 Fig. 2 Installation position Fig.

  • Page 155: Offset Gaps By

    Valve gear, servicing Página 2 de 49 control housing Spread/stretch seal as little as possible when replacing Offset gaps by http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 156 Valve gear, servicing Página 3 de 49 15-53 4 - Exhaust camshaft Check radial clearance with Plastigage, Wear limit: 0.1 mm Run-out: max. 0.01 mm Checking axial clearance Fig. 1 Identification and valve timing Fig. 5 Removing installing Page 15-69 5 - Control housing Lightly...
  • Page 157 Valve gear, servicing Página 4 de 49 installing Fig. 7 Removing installing Page 15-69 Removing installing camshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...

  • Page 158: Fig

    Valve gear, servicing Página 5 de 49 15-54 6 - Camshaft roller chain Mark direction of rotation. before removing (installation position) Page 13- , Fig. 1 Installing Page 15-39 Adjusting valve timing 7 - Exhaust camshaft timing adjuster Marking: Turn engine over only when...
  • Page 159 Valve gear, servicing Página 6 de 49 8 - 60 Nm + turn (90 ) further Replace Contact surface of sensor wheel on bolt head must be dry for assembly remove install, use a 32 mm open wrench camshaft counter- support Page 15-69...
  • Page 160 Valve gear, servicing Página 7 de 49 15-55 9 - Intake camshaft timing adjuster Markings: Turn engine over only when camshaft timing adjuster installed Checking camshaft timing adjustment Page 15-82 Installing Page 15-39 Adjusting valve timing 10 - Cylinder head height Minimum height: a...

  • Page 161: Fig

    Valve gear, servicing Página 8 de 49 12 - Cylinder head Check distortion Page 15-9 Fig. 1 Removing installing Page 15-25 Reworking valve seats Page 15- After replacement replace the entire coolant http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 162 Valve gear, servicing Página 9 de 49 15-56 13 - Support element Check axial clearance camshaft before installation Fig. 1 Do not interchange With hydraulic valve clearance compensation 14 - Valve stem seal Replacing Page 15-92 15 - Retaining clip Check seated securely...
  • Page 163 Valve gear, servicing Página 10 de 49 for easy movement running contact surfaces securing clip to clip onto support element when installing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...

  • Page 164: Position To

    Valve gear, servicing Página 11 de 49 15-57 17 - Valve spring Observe installation position Removing installing Page 15-92 Replacing valve stem seals 18 - Valve spring plate 19 - Valve cotters Intake camshaft bearing Before installing bearing cap 7, lightly grease contact...
  • Page 165 Valve gear, servicing Página 12 de 49 installing camshaft http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 166 Valve gear, servicing Página 13 de 49 15-58 21 - Intake camshaft Check radial clearance with Plastigage, Wear limit: 0.1 mm Run- out: max. 0.01 Checking axial clearance Fig. 1 Identification and valve timing Fig. 5 Removing installing Page 15-69 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 167 Valve gear, servicing Página 14 de 49 15-59 Fig. 1 Camshafts, checking axial clearance Special tools and equipment VW 387 Universal dial gauge bracket Dial gauge Test sequence Perform measurements with support elements and roller rocker fingers removed. Intake camshaft - Install bearing cap 7 and tighten to 5 Nm and turn (45 ).
  • Page 168 Valve gear, servicing Página 15 de 49 15-60 Fig. 2 Greasing contact surfaces of bearing caps 7 and 8 lightly before installing Special tools and equipment G 052 723 A2 Grease Work sequence - Before installing, lightly grease contact surfaces on both sides of bearing caps 7 and 8 (hatched areas only) with grease G 052 723 A2.
  • Page 169 Valve gear, servicing Página 16 de 49 15-61 Fig. 3 Installation position of camshaft bearing caps Points of bearing caps (arrow -A-) of intyake and exhaust camshafts face outward. Identifications on bearing caps are legible when read from intake side. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 170 Valve gear, servicing Página 17 de 49 15-62 Fig. 4 Valve dimensions Note: Valves must not be reworked. Only lapping-in is permitted. Valve dimensions for intake valves Dimension Short Long intake intake valve valve diameter 31.00 31.00 diameter 5.96 5.96 102.20 136.10 Valve dimensions for exhaust...
  • Page 171 Valve gear, servicing Página 18 de 49 15-63 Fig. 5 Camshaft identification, valve timing Camshaft identification Identification between No. 4 cyl. and No. 5 cyl. cam pair of respective camshaft. Camshaft Identification A - Exhaust camshaft 101 Index B - Intake camshaft 102 Index Valve timing at 1 mm valve lift...
  • Page 172 Valve gear, servicing Página 19 de 49 15-64 Fig. 6 Disassembling and assembling control housing 1 - Guide rail: Clipped onto control housing 2 - Control housing: Replaced complete with Valve -1- for camshaft adjustment - N205- and Camshaft adjustment valve 1 (exhaust) - N318-.
  • Page 173 Valve gear, servicing Página 20 de 49 15-65 Valve seats, reworking Special tools and equipment Depth gauge Valve seat refacing tool Work sequence Note: When repairing engines with leaking valves, it is not sufficient to rework or replace valve seats and valves.
  • Page 174 Valve gear, servicing Página 21 de 49 15-66 The maximum permissible reworking dimension is calculated as follows: - Insert valve and press firmly against seat. Note: If the valve is to be replaced as part of a repair, use a new valve for the measuring.
  • Page 175 Valve gear, servicing Página 22 de 49 15-67 Example: Measured 10.6 distance 10.2 Minimum dimension Max. perm. 0.4 mm rework dimension* The max. permissible reworking dimension is shown as dimension "b" in illustrations for the reworking of valve seats. Reworking intake valve seat = Diameter 30.6 mm = Max.
  • Page 176 Valve gear, servicing Página 23 de 49 15-68 Reworking exhaust valve seat = Diameter 26.7 mm = Max. permissible reworking dimension* = 1.2...1.7 mm = Max. diameter 29.0 mm = Radius 2.0 mm = Lower edge of cylinder head = 45 valve seat angle = 30 upper correction angle = 60 lower correction angle How to calculate the max.
  • Page 177 Valve gear, servicing Página 24 de 49 15-69 Camshafts, removing installing (with cylinder head installed) Special tools equipment T10068 Camshaft V.A.G 1331 Torque wrench (5...50 V.A.G 1332 Torque wrench (40...200 AMV 174 004 01 Sealing compound AMV 188 001 02 Sealing compound G 052 723...
  • Page 178 Valve gear, servicing Página 25 de 49 15-70 Removing CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
  • Page 179 Valve gear, servicing Página 26 de 49 15-71 - Disconnect 4-pin connector (arrow) from Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-. - Drain coolant Page 19-15 - Remove coolant thermostat housing Page 19-6 , Parts of cooling system, engine side.
  • Page 180 Valve gear, servicing Página 27 de 49 15-72 - Remove camshaft roller chain tensioner (arrow). - Disconnect connections from following components on cover: Camshaft Position (CMP) sensor -G40- -1-, Camshaft Position (CMP) sensor 2 -G163- -2-, Valve -1- for camshaft adjustment -N205- -3-, Camshaft adjustment valve 1 -N318- -4-.
  • Page 181 Valve gear, servicing Página 28 de 49 15-73 - Remove camshaft cover Page 15-11 Removing and installing camshaft. - Mark roller chains before removing (e.g. with paint, arrow pointing in direction of rotation). Note: Do not mark chain with a punched mark, notch or similar! - First remove exhaust camshaft timing adjuster.
  • Page 182 Valve gear, servicing Página 29 de 49 15-74 - Remove control housing from cylinder head (arrows). - Pull control housing carefully of camshaft seals. A - Intake camshaft - First remove bearing caps 1 and - Remove bearing caps 3 and 11. - Remove bearing cap 7.
  • Page 183 Valve gear, servicing Página 30 de 49 15-75 B - Exhaust camshaft - First remove bearing caps 2 and - Remove bearing caps 4 and 12. - Remove bearing cap 8. - Loosen bearing caps 6 and 10 alternately and diagonally. - Carefully remove camshafts and place on a clean surface.
  • Page 184 Valve gear, servicing Página 31 de 49 15-76 Installing Conditions When camshafts are installed, No. 1 Cyl. cams must point upward. Pistons must not be positioned at TDC. - Insert support element in cylinder head and fit roller rocker finger onto respective valve stem end / support element.
  • Page 185 Valve gear, servicing Página 32 de 49 15-77 Note: Observe installation position of bearing caps: Points of bearing caps (arrow -A- ) of intake and exhaust camshafts face outward. Identifications on bearing caps are legible when read from intake side. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 186 Valve gear, servicing Página 33 de 49 15-78 A - Intake camshaft - Lubricate hatched contact surface of bearing cap 7 from both sides lightly with grease G 052 723 A2 before installation Page 15-60 Fig. 2 - Tighten bearing caps 5 and 9 alternately and diagonally to 5 Nm turn (45 ).
  • Page 187 Valve gear, servicing Página 34 de 49 15-79 B - Exhaust camshaft - Lubricate hatched contact surface of bearing cap 8 from both sides lightly with grease G 052 723 A2 before installation Page 15-60 Fig. 2 - Tighten bearing caps 6 and 10 alternately and diagonally to 5 Nm turn (45 ).
  • Page 188 Valve gear, servicing Página 35 de 49 15-80 - Position camshafts in cylinder head to TDC No. 1 cylinder. Camshaft bar T10068 must engage in both shaft grooves. Note: If the camshaft bar cannot be engaged in the camshafts, turn camshafts in direction of rotation past TDC No.
  • Page 189 Valve gear, servicing Página 36 de 49 15-81 - Remove old sealing compound from 3 mm holes in cylinder head gasket (arrows). Note: When the cylinder head is installed the holes in the cylinder head gasket are only half visible. The rest of the assembly is basically in reverse order to the disassembling sequence.
  • Page 190 Valve gear, servicing Página 37 de 49 15-82 Camshaft adjustment, checking Function The camshaft timing adjustment is dependent upon load and speed. Oil pressure is directed to the camshaft timing adjuster (mechanical adjustment unit) by the camshaft timing adjustment solenoid valve and the camshaft adjuster then adjusts the camshaft.
  • Page 191 Valve gear, servicing Página 38 de 49 15-83 Test conditions Fuses must be OK. Battery voltage must be at least 11.5 V. All electrical consumers, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 192 Valve gear, servicing Página 39 de 49 15-84 If activation is OK.: Checking function of camshaft timing adjuster Test conditions Coolant temperature must be at least 85 C, display group 1, display zone 2. Test sequence - Connect V.A.G 1551 Scan Tool (or V.A.G 1552). Start engine and select "Address word"...
  • Page 193 Valve gear, servicing Página 40 de 49 15-85 Indicated on display: (1...4 display System in basic setting 1 zones) Only continue with the test when: Coolant temperature is above 85 C -Display zone 2- Checking intake camshaft timing adjustment - Change to display group 94 as follows: - Press C key.
  • Page 194 Valve gear, servicing Página 41 de 49 15-86 - Hold brake pedal and accelerator down until display in display zone 3 jumps from "Test OFF" to "Test ON". - Continue to hold brake pedal and accelerator down until display zone 3 displays specification "Syst.
  • Page 195 Valve gear, servicing Página 42 de 49 15-87 If no DTC is stored in DTC memory: - Press keys 0 and 6 for function "End output" and confirm entry with Q key. - Switch ignition off. - Check Camshaft Position (CMP) sensors -G40- and -G163- (connections may be interchanged): Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 196 Valve gear, servicing Página 43 de 49 15-88 Check exhaust camshaft timing adjustment - Change to display group 96 as follows: - Press C key. Indicated on display Basic setting Input display group number XXX - Press keys 0, 9 and 6 for "Display group number 96"...
  • Page 197 Valve gear, servicing Página 44 de 49 15-89 - Release brake and accelerator pedals. If "Sys. OK." appears in display zone 3: - Press key. - Press keys 0 and 6 for function "End output" and confirm entry with Q key. - Switch ignition off.
  • Page 198 Valve gear, servicing Página 45 de 49 15-90 If no DTC is stored in DTC memory: - Press keys 0 and 6 for function "End output" and confirm entry with Q key. - Switch ignition off. - Check Camshaft Position (CMP) sensors -G40- and -G163- (connections may be interchanged): Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 199 Valve gear, servicing Página 46 de 49 15-91 Valve guides, checking Special tools and equipment VW 387 Universal dial gauge bracket Dial gauge Test sequence - Insert a new valve into guide. Note: The end of the valve stem must be flush with the guide.

  • Page 200: Installation Tool (Funnel)

    Valve gear, servicing Página 47 de 49 15-92 Valve stem seals, replacing (with cylinder head installed) Special tools equipment 541/1A Assembly lever with press piece VW 541/6 2036 Assembly tool with adapter plate 2036/1 3122 B Spark plug wrench 3364 Puller 3365 Installation...
  • Page 201 Valve gear, servicing Página 48 de 49 15-93 V.A.G 1331 Torque wrench (5...50 Nm) Removing - Remove camshafts Page 15- - Remove roller rocker finger together with support elements and place on a clean surface. Note: Ensure the roller rocker fingers and the support elements are not interchanged.
  • Page 202 Valve gear, servicing Página 49 de 49 15-94 - Pull off valve stem seals with puller 3364. Installing - Prevent damage to new valve stem seals by sliding plastic sleeve -A- over valve stem. - Oil sealing lip of valve stem seal - B- insert in fitting tool 3365 and carefully push onto valve guide.

  • Page 203: Fig

    Lubrication system components, servicing Página 1 de 24 17-1 Lubrication system components, servicing Note: When working on the engine it should be secured to assembly stand VW 313 using engine bracket 3269 or VW 540 and supplementary set 540/1 B. The oil level must not be above the max.
  • Page 204 Lubrication system components, servicing Página 2 de 24 17-2 Disassembling and assembling oil filter housing Page 17-9 Disassembling and assembling oil pump Page 17-12 Checking oil pressure and oil pressure switch Page 17-19 Oil system capacity Fluid Capacity Chart Engine oil specifications New VW standard (specially developed, age resistant) Initial filling: VW standard: 503 00 (VW TL...
  • Page 205 Lubrication system components, servicing Página 3 de 24 17-3 1 - 8 Nm Secured to intake manifold 2 - Dipstick Oil level must not exceed the max. mark! Markings Fig. 2 3 - Guide tube dipstick Secured by a bolt to intake manifold 4 - Cylinder...
  • Page 206 Lubrication system components, servicing Página 4 de 24 17-4 5 - Oil non- return valve, 5 Observe installation position Clean if badly soiled note Page 17-1 6 - 10 Nm 7 - Oil pump drive cover 8 - O-ring Replace Lubricate before installing...
  • Page 207 Lubrication system components, servicing Página 5 de 24 17-5 13 - Drive shaft For oil pump drive 14 - Oil spray crankshaft bearings 2...7 piston cooling Opening pressure: 2.0 bar Removing installing Fig. 1 See note Page 17-1 15 - Oil pump Disassembling assembling Page 17-12...
  • Page 208 Lubrication system components, servicing Página 6 de 24 locking compound D 000 600 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 209 Lubrication system components, servicing Página 7 de 24 17-6 18 - Oil drain plug, 30 Replace if leaking 19 - Oil pan Removing installing Page 17-15 20 - 12 Nm 21 - Oil filter housing See note Page 17-1 Disassembling assembling Page 17-9 Coolant...
  • Page 210 Lubrication system components, servicing Página 8 de 24 17-7 Fig. 1 Removing and installing oil spray jet Special tools and equipment 4 mm diameter drift 6 mm diameter drift Note: Oil spray jets are installed in main bearings 2..7. Removing - Press oil spray jet out toward bearing using a 4 mm diameter drift.
  • Page 211 Lubrication system components, servicing Página 9 de 24 17-8 Fig. 2 Dipstick markings 1 - Max. mark 2 - Min. mark a - Area above hatched field up to max. mark: Do not replenish engine oil! b - Oil level within hatched field: Engine oil may be replenished c - Area from min.
  • Page 212 Lubrication system components, servicing Página 10 de 24 17-9 Oil filter housing, disassembling assembling 1 - Sealing plug, 10 If seal is leaking nip open replace. 2 - 1.4 bar Oil pressure switch - F1-, 20 Marking: black If seal is leaking nip open replace.
  • Page 213 Lubrication system components, servicing Página 11 de 24 17-10 5 - Oil cooler Ensure clearance to adjacent components Coat contact area outside seal with sealing compound AMV 188 001 02 Note Page 17-1 Coolant hose connection diagram Page 19- 6 - Seal Replace Lubricate before...
  • Page 214 Lubrication system components, servicing Página 12 de 24 cooler before installing cooler http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 215 Lubrication system components, servicing Página 13 de 24 17-11 9 - 23 Nm 10 - Oil filter element Observe change intervals Note Page 17-1 11 - Oil filter lower part, 25 Drain before removing With by- pass valve, Opening pressure: 2.50 bar 12 - Oil drain...
  • Page 216 Lubrication system components, servicing Página 14 de 24 17-12 Oil pump, disassembling assembling 1 - Drive shaft For oil pump drive 2 - Oil pump housing 3 - 23 Nm 4 - Gears Checking backlash Fig. 1 Checking axial clearance Fig.
  • Page 217 Lubrication system components, servicing Página 15 de 24 17-13 7 - Oil pressure pipe Coat cylinder block and oil pump housing with sealing compound AMV 188 001 02 8 - 8 Nm 9 - Seal Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 218 Lubrication system components, servicing Página 16 de 24 17-14 Fig. 1 Checking oil pump backlash Special tools and equipment Feeler gauge Wear limit: 0.20 mm Fig. 2 Checking oil pump axial clearance Special tools and equipment Straight edge Feeler gauge Wear limit: 0.10 mm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 219 Lubrication system components, servicing Página 17 de 24 17-15 Oil pan, removing and installing Special tools and equipment VAG 1331 Torque wrench (5...50 Nm) D 176 404 A2 Silicone sealing compound Hand drill with plastic brush attachment Flat scraper Protective goggles Removing - Remove center, left and right insulation trays: Repair Manual, Body Exterior, Repair Group...
  • Page 220 Lubrication system components, servicing Página 18 de 24 17-16 - If necessary loosen oil pan with light blows of a rubber mallet. - Remove sealant residue from cylinder block with a flat scraper. - Remove sealant residue from pan with a rotating brush, e.g.
  • Page 221 Lubrication system components, servicing Página 19 de 24 17-17 - Cut off tube nozzle at front marking (nozzle approx. 3 mm diameter). - Apply silicone sealing compound, as shown, to clean oil pan sealing surface. Sealing compound bead must be: 2...3 mm thick, and run on inside of bolt holes (arrows).
  • Page 222 Lubrication system components, servicing Página 20 de 24 17-18 - Apply silicone sealing compound bead as illustrated to clean sealing surface of oil pan. - Install oil pan immediately and tighten all pan bolts lightly. - Tighten oil pan bolts to 12 Nm. - Tighten bolts for pan/transmissionto 45 Nm.
  • Page 223 Lubrication system components, servicing Página 21 de 24 17-19 pressure and oil pressure switch, checking Special tools equipment VAG 1342 pressure tester 1342/14 Adapter VAG 1527 B Diode test lamp VAG 1594 A Adapter http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 224 Lubrication system components, servicing Página 22 de 24 17-20 Test conditions Engine oil level OK, checking Page 17-8 Fig. 2 Engine oil temperature at least 80 C (coolant fan must have run once). Selector lever must be in position "P" or "N"...
  • Page 225 Lubrication system components, servicing Página 23 de 24 17-21 - Remove Oil pressure switch -F1- and screw into tester. - Screw tester VAG 1342 with adapter VAG 1342/14 into oil filter bracket instead of oil pressure switch. Note: Observe installation position of adapter: The tapered connecting socket of the adapter is screwed to the pressure hose of the tester.
  • Page 226 Lubrication system components, servicing Página 24 de 24 17-22 Checking oil pressure - Check oil pressure at different revolutions: 2,000 rpm: 3.0...5.5 bar above 2,000 rpm: maximum 7.0 bar. If the specifications are not attained: - Repair mechanical damage, e.g. bearing damage.
  • Page 227 Cooling system components, servicing Página 1 de 43 19-1 Cooling system components, servicing CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original...
  • Page 228 Cooling system components, servicing Página 2 de 43 19-2 Perform cooling system leakage test with cooling system tester VAG 1274 and adapters VAG 1274/8 and VAG 1274/9. Parts of cooling system, body side Page 19-3 Parts of cooling system, engine side Page 19-6 Coolant hose connection diagram Page...
  • Page 229 Cooling system components, servicing Página 3 de 43 19-3 Components of cooling system, body side 1 - Radiator Removing installing Page 19-22 After replacement also replace entire coolant 2 - O-ring Replace damaged 3 - Upper coolant hose Secured radiator with a quick release...
  • Page 230 Cooling system components, servicing Página 4 de 43 Observe installation position 6 - Washer http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 231 Cooling system components, servicing Página 5 de 43 19-4 7 - Air ducting 8 - 5 Nm 9 - Retaining clip Check secure seating 10 - Right coolant fan - V35- Checking Page 19-31 Removing installing Page 19-22 11 - Coolant fan -V7- Checking Page...
  • Page 232 Cooling system components, servicing Página 6 de 43 fan - http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 233 Cooling system components, servicing Página 7 de 43 19-5 14 - Lower coolant hose Secured radiator with a quick release coupling Check seated securely Coolant hose connection diagram Page 19- 15 - Connector Coolant Control (FC) Thermal switch - F18- 16 - Coolant Control (FC)
  • Page 234 Cooling system components, servicing Página 8 de 43 92...97 C, Off: 84...91 2nd. speed - 99...105 C, Off: 91...98 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 235 Cooling system components, servicing Página 9 de 43 19-6 Components of cooling system, engine side 1 - Coolant pipe Secured exhaust manifold together with heat shield 2 - 10 Nm 3 - To heat exchanger Coolant hose connection diagram Page 19- 4 - From heat exchanger Coolant...
  • Page 236 Cooling system components, servicing Página 10 de 43 Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 237 Cooling system components, servicing Página 11 de 43 19-7 6 - Cable guide coolant hoses wiring harness 7 - 8 Nm 8 - Upper coolant hose To top radiator Check secure seating Coolant hose connection diagram Page 19- 9 - Bracket wiring harness 10 - Lower...
  • Page 238 Cooling system components, servicing Página 12 de 43 connection diagram Page 19- 11 - To cylinder block Coolant hose connection diagram Page 19- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 239 Cooling system components, servicing Página 13 de 43 19-8 12 - After-Run Coolant pump - V51- Secured cylinder block by a bracket Checking Page 19-33 13 - Oil cooler Disassembling assembling Page 17-9 Disassembling assembling oil filter housing 14 - O-ring Replace 15 - From cylinder...
  • Page 240 Cooling system components, servicing Página 14 de 43 19-9 18 - Coolant pump Observe installation position Check for ease of movement damaged leaking replace complete Removing installing Page 19-26 19 - 20 Nm 20 - Belt pulley coolant pump Removing installing ribbed belt...
  • Page 241 Cooling system components, servicing Página 15 de 43 coolant pump wrench 1590 to loosen tighten Page 19- Removing installing coolant pump 22 - 25 Nm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 242 Cooling system components, servicing Página 16 de 43 19-10 23 - Expansion tank Perform leak test on cooling system with cooling system tester VAG 1274 and adapter VAG1274/8 Test pressure: 1.4...1.6 Observe markings Page 19-15 Draining and filling cooling system 24 - Seal Replace damaged...
  • Page 243 Cooling system components, servicing Página 17 de 43 open at a pressure 1.4...1.6 26 - Seal Replace 27 - Thermostat housing Disassembling assembling Page 19-13 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 244 Cooling system components, servicing Página 18 de 43 19-11 Coolant hose connection diagram Transmission oil cooler Only models with an automatic transmission 2 - Thermostat housing 3 - Cable guide coolant hoses wiring harness 4 - Upper coolant hose 5 - Lower coolant hose 6 - Radiator...
  • Page 245 Cooling system components, servicing Página 19 de 43 19-12 10 - Coolant pipe Between coolant pump and thermostat housing 11 - Coolant pump 12 - Cylinder head Expansion tank 14 - Coolant pipe Secured exhaust manifold together with heat shield 15 - Throttle valve control...
  • Page 246 Cooling system components, servicing Página 20 de 43 19-13 Coolant thermostat housing, disassembling assembling Note: Routing coolant hoses to thermostat housing Page 19-6 , Parts of cooling system, engine side. 1 - O-ring Replace damaged 2 - Retaining clip Check seated securely 3 - Thermostat...
  • Page 247 Cooling system components, servicing Página 21 de 43 19-14 6 - Coolant thermostat Observe installation position Checking: Heat up thermostat in water Starts to open approx. 80 C Ends at approx. 105 C Opening stroke at least 7 mm 7 - Unions 8 - Seal Replace Engine...
  • Page 248 Cooling system components, servicing Página 22 de 43 necessary before removing components Checking: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 10 - Plug Release pressure in cooling system if necessary before removing components http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 249 Cooling system components, servicing Página 23 de 43 19-15 Cooling system, draining and filling Special tools and equipment T10007 Refractometer VAG1274/8 Adapter VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 VAS 5024 Assembly tool for spring- type clips Not illustrated: VAS 6096 Coolant system...
  • Page 250 Cooling system components, servicing Página 24 de 43 19-16 Draining - Open cap on coolant expansion tank. WARNING! Steam can be released when removing the cap from the expansion tank. Cover the cap with a cloth and open carefully. - Remove center insulation tray: Repair Manual, Body Exterior, Repair Group 50 - Pull out lower coolant hose...
  • Page 251 Cooling system components, servicing Página 25 de 43 19-17 - To drain coolant from engine also remove coolant hoses from oil cooler (arrows). Note: Observe waste disposal regulations! Filling Note: Only use coolant additive G 12 in accordance with TL VW 774 D. Identification color: red Under no circumstances must G 12 be mixed with other coolant...
  • Page 252 Cooling system components, servicing Página 26 de 43 19-18 Protection against frost must be assured to approx. -25 C (in arctic climatic countries to approx. -35 C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries.
  • Page 253 Cooling system components, servicing Página 27 de 43 19-19 Work sequence - Install lower coolant hose and secure with retaining clamp (arrow). - Slide coolant hoses onto oil cooler unions (arrows) and secure with spring-type clamps. - Install center insulation tray: Repair Manual, Body Exterior, Repair Group 50 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 254 Cooling system components, servicing Página 28 de 43 19-20 Without using coolant system charging unit VAS 6096 - Fill coolant slowly up to top mark of hatched field on expansion tank. Using coolant system charging unit VAS 6096 - Screw adapter V.A.G1274/8 onto expansion tank.
  • Page 255 Cooling system components, servicing Página 29 de 43 19-21 - Check coolant level and top up coolant if necessary: At normal engine operating temperature coolant level must reach top mark of hatched field. When engine is cold coolant level should be around middle of hatched field.
  • Page 256 Cooling system components, servicing Página 30 de 43 19-22 Radiator and coolant fan, removing and installing Special tools and equipment T10007 Refractometer VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 VAS 5024 Assembly tool for spring- type clips http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 257 Cooling system components, servicing Página 31 de 43 19-23 Removing - Remove center, left and right insulation trays: Repair Manual, Body Exterior, Repair Group - Disconnect connectors from thermal switch and coolant fan. - Remove front bumper: Repair Manual, Body Exterior, Repair Group - Bring lock carrier into service position: Repair Manual, Body Exterior, Repair Group - Drain coolant...
  • Page 258 Cooling system components, servicing Página 32 de 43 19-24 - Remove radiator securing bolts from side of radiator and take radiator with fans out downward. Installing Install in reverse sequence ; note the following points: - Check electrical connections and routing: Electrical Wiring Diagrams, Troubleshooting &...
  • Page 259 Cooling system components, servicing Página 33 de 43 19-25 - Remove securing bolts from fan shroud and remove fan shroud and fan. - Remover radiator securing bolts from side of radiator. - Remove condenser from radiator. - Secure condenser to body, so that refrigerant lines/hoses are not under stress.
  • Page 260 Cooling system components, servicing Página 34 de 43 19-26 Coolant pump, removing and installing (with engine installed) Special tools and equipment 10-222A Engine support bracket with legs 10- 222A/1 T10007 Refractometer VAG 1306 Drip tray VAG 1331 Torque wrench (5...50 VAG 1332 Torque wrench...
  • Page 261 Cooling system components, servicing Página 35 de 43 19-27 VAS 5024 Assembly tool for spring-type clips VAS 5085 Ladder Removing - Remove engine cover. - Remove center and right insulation trays: Repair Manual, Body Exterior, Repair Group 50 - Remove ribbed belt Page 13- - Pull off crankcase breather connecting hose between cylinder...
  • Page 262 Cooling system components, servicing Página 36 de 43 19-28 - 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).
  • Page 263 Cooling system components, servicing Página 37 de 43 19-29 - 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 264 Cooling system components, servicing Página 38 de 43 19-30 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 20 Nm. - Align engine assembly mountings Page 10- , Aligning engine and transmission...
  • Page 265 Cooling system components, servicing Página 39 de 43 19-31 Coolant fan, checking Special tools and equipment VAG 1594 A Adapter set Wiring diagram Test conditions Main fuses must be OK. Coolant Fan Control (FC) Thermal switch -F18- is OK. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 266 Cooling system components, servicing Página 40 de 43 19-32 Test sequence - Remove left-hand insulation tray: Repair Manual, Body Exterior, Repair Group - Disconnect 3-pin connector from Coolant Fan Control (FC) Thermal switch -F18-. - Bridge contact -1- and contact -2- of connector using adapter cables from VAG 1594 A.
  • Page 267 Cooling system components, servicing Página 41 de 43 19-33 After-Run Coolant pump -V51-, checking Special tools and equipment VAG 1527 B Diode test lamp VAG 1594 A Adapter set Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 268 Cooling system components, servicing Página 42 de 43 19-34 Test conditions All fuses must be OK. Test sequence - Remove center insulation tray: Repair Manual, Body Exterior, Repair Group 50 - Disconnect 2-pin connector from After-Run Coolant pump -V51- (arrow). Checking function - Connect contacts of After-Run Coolant pump -V51- to battery...
  • Page 269 Cooling system components, servicing Página 43 de 43 19-35 If the coolant pump does not start: - Replace After-Run Coolant pump -V51-. If the coolant pump starts: Checking activation - Switch ignition off and on again. - Connect diode test lamp VAG 1527 B to disconnected connector for After-Run Coolant pump -V51- with adapter cables from VAG...
  • Page 270 Components of fuel supply system, servicing Página 1 de 42 20-1 Components of fuel supply system, servicing Note: Hose connections are secured with either spring-type or clamp-type clips. Always replace clamp-type clips with spring type clips. Fuel hoses on engine must only be secured with spring-type clips.
  • Page 271 Components of fuel supply system, servicing Página 2 de 42 20-2 Fuel tank, fuel filler attachments, removing installing 1 - Sealing 2 - Seal Replace damaged 3 - Securing bolt 4 - Tank flap unit With rubber 5 - Breather line Black Check if...
  • Page 272 Components of fuel supply system, servicing Página 3 de 42 20-3 7 - Breather line White Check secure seating Press together at front release From union piece Page item - 8 - Gravity valve remove valve unclip upward out of support Check valve...
  • Page 273 Components of fuel supply system, servicing Página 4 de 42 Replace damaged 10 - Change- over valve remove valve unclip sideways out of socket Before installing remove sealing cap item - 1 - Checking Fig. 2 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 274 Components of fuel supply system, servicing Página 5 de 42 20-4 11 - Breather line Black Check for secure seating From union piece Page 20-42 , item 12 - Pressure retention valve Checking Fig. 3 13 - Breather line Black Check for secure seating 14 - Fuel tank...
  • Page 275 Components of fuel supply system, servicing Página 6 de 42 20-5 17 - 25 Nm Clamping nut, 2 Nm 19 - Fuel tank cover Securing strap Note differing lengths Installation position: Fixing point (holes) point in direction of travel (forward) 21 - Supply line Black...
  • Page 276 Components of fuel supply system, servicing Página 7 de 42 Liter VR6 4V Fuel Injection & Ignition, Engine Code (s): BDF, Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 277 Components of fuel supply system, servicing Página 8 de 42 20-6 22 - Fuel filter Installation position: Arrow points in direction of flow 23 - Screw- type clip Observe installation position Fig. 4 24 - Breather line White Check secure seating Clipped onto...
  • Page 278 Components of fuel supply system, servicing Página 9 de 42 tank opening Moisten with fuel only when installing fuel delivery unit flange http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 279 Components of fuel supply system, servicing Página 10 de 42 20-7 26 - Fuel delivery unit Observe installation position of flange on fuel tank Fig. 1 Removing installing Page 20-15 Removing installing fuel gauge sender Page 20- Checking fuel pump Page 20- Clean strainer...
  • Page 280 Components of fuel supply system, servicing Página 11 de 42 secure seating Clipped onto side of fuel tank When puling off flange and fuel filter press release button on connecting piece http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 281 Components of fuel supply system, servicing Página 12 de 42 20-8 29 - Return line Blue or with blue marking Clipped onto side of fuel tank Check secure seating To remove from flange press release button on connecting piece From fuel return pipe...
  • Page 282 Components of fuel supply system, servicing Página 13 de 42 for fuel gauge Fuel Pump (FP) - 31 - 10 Nm http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 283 Components of fuel supply system, servicing Página 14 de 42 20-9 Fig. 1 Installation position of fuel delivery unit flange Marking on sender must align with marking on fuel tank (arrows). Blue or blue marked return line -1- to union with identification -R-. Black supply line -2- to union with identification -V-.
  • Page 284 Components of fuel supply system, servicing Página 15 de 42 20-10 Fig. 3 Checking pressure retention valve - Check direction of valve flow: A) Union 1 - 1: Flow in both directions Union -2- is closed B) Union 1 - 2: Flow in both directions Union -3- is closed C) Union 1 - 2:...
  • Page 285 Components of fuel supply system, servicing Página 16 de 42 20-11 Fig. 4 Installation position of screw-type clip for fuel filter Note: The fuel filter is illustrated viewed from the front. - Install screw-type clip (arrow) as shown in illustration. Ensure sufficient clearance between clip fastener and fuel tank.
  • Page 286 Components of fuel supply system, servicing Página 17 de 42 20-12 Safety precautions when working on the fuel supply system CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g.
  • Page 287 Components of fuel supply system, servicing Página 18 de 42 20-13 Before commencing work, switch on exhaust extraction system and place an extraction hose close to sender opening in the fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan with a displacement greater than 15 m /h can be...
  • Page 288 Components of fuel supply system, servicing Página 19 de 42 20-14 Rules for cleanliness When working on the fuel supply/injection system, pay careful attention to the following 5 rules: Thoroughly clean all unions and the adjacent areas before disconnecting. Place parts that have been removed on a clean surface and cover.
  • Page 289 Components of fuel supply system, servicing Página 20 de 42 20-15 Fuel delivery unit , removing and installing Special tools and equipment 3217 Union nut spanner VAG 1332 Torque wrench (40...200 Nm) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 290 Components of fuel supply system, servicing Página 21 de 42 20-16 Removing - Observe safety precautions before starting work Page 20-12 - Check whether a coded radio is installed. If so, obtain anti-theft coding. - With ignition switched off disconnect battery Ground strap.
  • Page 291 Components of fuel supply system, servicing Página 22 de 42 20-17 - Seal lines to avoid contamination of fuel system. - Remove union nut with spanner 3217. - Pull fuel delivery unit and seal out of opening in fuel tank. Note: If the delivery unit is to be replaced then drain old delivery unit before...
  • Page 292 Components of fuel supply system, servicing Página 23 de 42 20-18 Note installation position of fuel delivery unit flange: The marking on flange must align with marking on fuel tank (arrows). Make sure tight fit of fuel hoses. After installing fuel delivery unit, check that the supply, return and breather lines are still clipped onto fuel tank.
  • Page 293 Components of fuel supply system, servicing Página 24 de 42 20-19 Fuel gauge sender, removing and installing Removing - Remove fuel delivery unit Page 20-15 - Release connections for wires -3- and -4- and disconnect. - Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sender out downward (arrows).
  • Page 294 Components of fuel supply system, servicing Página 25 de 42 20-20 Fuel tank, removing and installing Special tools and equipment VAG 1331 Torque wrench (5...50 VAG 1383 A Engine/transmission jack http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 295 Components of fuel supply system, servicing Página 26 de 42 20-21 Removing - Observe safety precautions before starting work Page 20-12 - Check whether a coded radio is installed. If so, obtain anti-theft coding. - With ignition switched off disconnect battery Ground strap.
  • Page 296 Components of fuel supply system, servicing Página 27 de 42 20-22 - Remove cover from fuel delivery unit. - Remove 4-pin connector from flange (arrow). - Remove cover for fuel tank (arrows). http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 297 Components of fuel supply system, servicing Página 28 de 42 20-23 - Disconnect return line -2- (blue), supply line -1- (black) and breather line -3- (white) at connecting point. Note: Press buttons on hose couplings to do so. WARNING! Fuel supply lines are under pressure! Before removing from hose connections wrap a cloth around the connection.
  • Page 298 Components of fuel supply system, servicing Página 29 de 42 20-24 Note: After installing fuel gauge sender, check that the supply, return and breather pipes are still clipped onto the fuel tank. - Check DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 299 Components of fuel supply system, servicing Página 30 de 42 20-25 Crash fuel shut-off Function Models with an airbag are installed with a crash fuel shut-off system. It reduces the danger of a fire in a crash as the fuel pump is switched off via the fuel pump relay.
  • Page 300 Components of fuel supply system, servicing Página 31 de 42 20-26 Fuel pump, checking Special tools equipment 3217 Union nut spanner VAG 1318 Pressure gauge 1318/11 Adapter 1318/16 Hose adapter 1318/17 Adapter 1318/23 Adapter http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 301 Components of fuel supply system, servicing Página 32 de 42 20-27 VAG 1332 Torque wrench (40...200 1348/3A Remote control with adapter cable VAG 1348/3-2 VAG 1466 A Test system VAG 1527 B Diode test lamp VAG 1594 A Adapter VAG 1715 Multimeter Measuring container...
  • Page 302 Components of fuel supply system, servicing Página 33 de 42 20-28 Test conditions Fuse 28 must be OK. Battery voltage must be at least 11.5 V. All electrical consumers, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 303 Components of fuel supply system, servicing Página 34 de 42 20-29 If the fuel pump does not run: - Remove cover in front of fuse holder. - Pull fuse No. 28 (for fuel pump) out of fuse holder. - Connect remote control VAG 1348/3A to contact 28a to fuel pump and battery positive (+) using adapter cable VAG 1348/3-...
  • Page 304 Components of fuel supply system, servicing Página 35 de 42 20-30 - Connect diode test lamp VAG 1527 B to outer contacts of connector using adapter cables from VAG 1594 A. - Operate remote control. LED must light up LED does not light-up: - Locate and eliminate open circuit referring to wiring diagram: Electrical Wiring Diagrams,...
  • Page 305 Components of fuel supply system, servicing Página 36 de 42 20-31 Checking delivery rate Test conditions Voltage supply OK. Remote control VAG 1348/3A connected. Test sequence - Remove filler cap from fuel tank filler neck. - Disconnect supply hose -3- (with white marking) and collect fuel that may leak out with a cloth.
  • Page 306 Components of fuel supply system, servicing Página 37 de 42 20-32 - Connect pressure gauge VAG 1318 to fuel supply pipe using adapter VAG 1318/23 and VAG 1318/17. - Push hose adapter VAG 1318/16 onto adapter VAG 1318/11 on pressure gauge and hold hose in a measuring container.
  • Page 307 Components of fuel supply system, servicing Página 38 de 42 20-33 - Compare quantity of fuel delivered with nominal value. Minimum delivery cm /30 seconds Voltage at fuel pump with engine not running and pump running (approx. 2 volts less than battery voltage).
  • Page 308 Components of fuel supply system, servicing Página 39 de 42 20-34 If the minimum delivery rate is now attained: - Replace fuel filter. If the minimum delivery rate is again not attained: - Remove fuel delivery unit and check strainer filter for soiling.
  • Page 309 Components of fuel supply system, servicing Página 40 de 42 20-35 - Connect multimeter VAG 1715 to wire (arrow) for contact 1of 4-pin connector using current pick-up clamp. - Start engine and run at idling speed. - Measure current draw of fuel pump.
  • Page 310 Components of fuel supply system, servicing Página 41 de 42 20-36 Test sequence Note: With this check the fuel supply line connections from the fuel delivery unit to the point at which the pressure gauge VAG 1318 is connected will be checked for leaks at the same time.
  • Page 311 Components of fuel supply system, servicing Página 42 de 42 20-37 - Check pipe connections for leaks. If no wiring fault is detected: - Fuel pump faulty, replace fuel delivery unit Page 20-15 , Removing and installing fuel delivery unit. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 312 Evaporative Emissions (EVAP) system Página 1 de 29 20-38 Evaporative Emissions (EVAP) system Function Depending on air pressure and ambient temperature, fuel vapor will form above the level of fuel in the tank. The EVAP system prevents these HC emissions from escaping into the atmosphere.
  • Page 313 Evaporative Emissions (EVAP) system Página 2 de 29 20-39 The pressure retention valve prevents fuel vapors from being drawn from the tank when the solenoid valve is open and an intake manifold vacuum is present. It therefore ensures that the evacuation of the EVAP canister has priority.
  • Page 314 Evaporative Emissions (EVAP) system Página 3 de 29 20-40 During the diagnosis the Leak Detection Pump (LDP) -144- creates a pressure of 30 mbar in the EVAP system. When the pressure is attained the pump switches off. If the pressure drops below a predetermined value the pump switches on again.
  • Page 315 Evaporative Emissions (EVAP) system Página 4 de 29 20-41 Components of the EVAP system, servicing Note: Checking EVAP system for leaks Page 20- Components marked with an * are checked by On Board Diagnostic (OBD): Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 316 Evaporative Emissions (EVAP) system Página 5 de 29 Check seated securely Press together at front release pressure retention valve Page 20-3 item - 7 2 - Seal Replace damaged http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 317 Evaporative Emissions (EVAP) system Página 6 de 29 20-42 3 - Breather line Black Check seated securely change- over valve Page 20-4 item - 11 - 4 - Junction piece Connector Black, 3-pin 6 - Vacuum line intake manifold Page 20-44 item - 4 7 - Leak...
  • Page 318 Evaporative Emissions (EVAP) system Página 7 de 29 will be activated engine control module (pulsed) Checking resistance Page 20-60 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 319 Evaporative Emissions (EVAP) system Página 8 de 29 20-43 Connecting hose Pressure side 9 - 3 Nm 10 - Air filter for LDP Connecting hose Suction side 12 - Bracket 13 - 10 Nm 14 - EVAP canister In rear right wheel housing,...
  • Page 320 Evaporative Emissions (EVAP) system Página 9 de 29 20-44 EVAP canister system, assembly overview 1 - Tank flap unit 2 - Fuel tank 3 - Fuel delivery unit 4 - Intake manifold 5 - Fuel pressure regulator 6 - Fuel rail with injectors 7 - Fuel...
  • Page 321 Evaporative Emissions (EVAP) system Página 10 de 29 20-45 8 - EVAP canister purge regulator valve - N80- Installation position: Arrow points in direction of flow Valve will be activated engine control module (pulsed) Checking function Page 20-54 Checking activation: Repair Manual, 2.8 Liter VR6 4V...
  • Page 322 Evaporative Emissions (EVAP) system Página 11 de 29 13 - EVAP canister In rear right wheel housing, behind wheel housing liner http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 323 Evaporative Emissions (EVAP) system Página 12 de 29 20-46 Leak Detection Pump (LDP) - V144- In rear right wheel housing, behind wheel housing liner Valve will be activated engine control module (pulsed) Checking resistance Page 20-60 Checking activation: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 324 Evaporative Emissions (EVAP) system Página 13 de 29 20-47 EVAP system, checking for leaks Special tools equipment, testers V.A.G 1551 Scan Tool (or vehicle system tester V.A.G 1552) with cable VAG 1551/3 Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the new tester VAS 5051.
  • Page 325 Evaporative Emissions (EVAP) system Página 14 de 29 20-48 Selector lever must be in position "P" or "N" on models with an automatic transmission. Fuel pump relay -J17- must be OK, checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations No DTCs may be stored in DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 326 Evaporative Emissions (EVAP) system Página 15 de 29 20-49 Functional check Test conditions Throttle valve angle less than 4%, display group 3, display zone 3. Coolant temperature must be 85...110 C display group 4, display zone 3. Intake air temperature less than 80 C, display group 4, display zone 4.
  • Page 327 Evaporative Emissions (EVAP) system Página 16 de 29 20-50 - Press keys 0, 7 and 1 for "Display group number 71" and confirm entry with Q key. Note: The engine must not be loaded during this diagnosis, if this occurs the diagnosis will be interrupted and will not start again until the engine is revved-up.
  • Page 328 Evaporative Emissions (EVAP) system Página 17 de 29 20-51 - Leave engine running at idling speed until display zone 4 displays specification "Syst. OK.". If "Sys. OK." appears in display zone 4: - Press key. - Press keys 0 and 6 for function "End output" and confirm entry with Q key.
  • Page 329 Evaporative Emissions (EVAP) system Página 18 de 29 20-52 - Generate readiness code again if DTC memory has been erased or engine control module separated from permanent positive supply: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group If no DTC is stored in DTC memory: - Press keys 0 and 6 for function "End output"...
  • Page 330 Evaporative Emissions (EVAP) system Página 19 de 29 20-53 - Remove rear right wheel housing liner: Repair Manual, Body Exterior, Repair Group - Check to see if pressure hose between LDP and EVAP canister is leaking Page 20-43 , item - 8 - and replace if necessary.
  • Page 331 Evaporative Emissions (EVAP) system Página 20 de 29 20-54 EVAP canister purge regulator valve -N80-, checking In a no-current situation the solenoid valve is closed. Special tools and equipment V.A.G 1551 Scan Tool (or vehicle system tester V.A.G 1552) with cable VAG 1551/3 Note: All functions which could previously be performed with V.A.G 1551/1552...
  • Page 332 Evaporative Emissions (EVAP) system Página 21 de 29 20-55 Selector lever must be in position "P" or "N" on models with an automatic transmission. Fuel pump relay -J17- must be OK, checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations No DTCs may be stored in DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 333 Evaporative Emissions (EVAP) system Página 22 de 29 20-56 Functional check Test conditions Coolant temperature must be at least 85 C, display group 1, display zone 2. Test sequence - Connect V.A.G 1551 Scan Tool (or V.A.G 1552). Start engine and select "Address word" 01 of engine control module.
  • Page 334 Evaporative Emissions (EVAP) system Página 23 de 29 20-57 Only continue with the test when The coolant temperature is above 85 C -Display zone 2- - Change to display group 70 as follows: - Press C key. Indicated on display Basic setting Input display group number XXX - Press keys 0, 7 and 0 for "Display...
  • Page 335 Evaporative Emissions (EVAP) system Página 24 de 29 20-58 - Leave engine running at idling speed until display zone 4 displays specification TBV OK. Note: TBV stands for tank breather valve (EVAP canister purge regulator valve -N80-). If "TBV OK" appears in display zone 4: - Press key.
  • Page 336 Evaporative Emissions (EVAP) system Página 25 de 29 20-59 - Generate readiness code again if DTC memory has been erased or engine control module separated from permanent positive supply. Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group If no DTC is stored in DTC memory: - Press keys 0 and 6 for function "End output"...
  • Page 337 Evaporative Emissions (EVAP) system Página 26 de 29 20-60 Leak Detection Pump (LDP) - V144-, checking Special tools and equipment VAG 1526 A multimeter, Fluke 83 multimeter or equivalent VAG 1594 Adapter set http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 338 Evaporative Emissions (EVAP) system Página 27 de 29 20-61 Test conditions No DTCs may be stored in DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group Checking activation - Check activation of LDP -V144- via output Diagnostic Test Mode (DTM): Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 339 Evaporative Emissions (EVAP) system Página 28 de 29 20-62 Checking resistance - Remove rear right wheel housing liner: Repair Manual, Body Exterior, Repair Group 66 - Disconnect 3-pin connector (arrow) for Leak Detection Pump (LDP) -V144-. - Connect multimeter to measure resistance between contacts 1 and 3 of LDP -V144- using adapter cables from VAG 1594 A.
  • Page 340 Evaporative Emissions (EVAP) system Página 29 de 29 20-63 If the specifications are not attained: - Replace Leak Detection Pump (LDP) -V144- Page 20-42 , item - 7 -. - Check DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 341 Electronic Power Control (EPC) Página 1 de 13 20-64 Electronic Power Control (EPC) Function of EPC systems With the EPC system the throttle valve is not operated by the throttle pedal via a cable. There is no mechanical connection between accelerator and throttle valve.
  • Page 342 Electronic Power Control (EPC) Página 2 de 13 20-65 When the engine is running (under load) the engine control module can open or close the throttle valve independently of the accelerator pedal position sender. This means that the throttle valve can already be completely open even though the accelerator pedal is depressed half way.
  • Page 343 Electronic Power Control (EPC) Página 3 de 13 20-66 Electronic Power Control (EPC), servicing 1 - Mounting bracket 2 - Connector Black, 6-pin Gold plated contacts 3 - 10 Nm 4 - Throttle Position (TP) sensor - G79- adjustable TP sensor passes driver's requirements...
  • Page 344 Electronic Power Control (EPC) Página 4 de 13 Manual, 5 Spd. Automatic Transmission 09A On Board Diagnostic (OBD); Repair Group 01 5 - Bracket footwell cover Clipped onto accelerator pedal http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 345 Electronic Power Control (EPC) Página 5 de 13 20-67 Throttle Position (TP) sensor -G79- / Sender -2- accelerator pedal position - G185-, checking Special tools equipment VAG 1526 multimeter, Fluke 83 multimeter equivalent VAG 1594 A Adapter 1598/31 Test box V.A.G 1551 Scan Tool or...
  • Page 346 Electronic Power Control (EPC) Página 6 de 13 1551/1552 can also be performed with the new tester VAS 5051. Wiring diagram http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 347 Electronic Power Control (EPC) Página 7 de 13 20-68 Note: Only gold plated contacts may be used to service the contacts in the TP sensor / Sender for accelerator pedal position connection. Function Both the Throttle Position (TP) sensor -G79- and the Sender -2- for accelerator pedal position -G185- are located on the accelerator pedal and pass the driver's requirements...
  • Page 348 Electronic Power Control (EPC) Página 8 de 13 20-69 Test sequence - Connect V.A.G 1551 Scan Tool (or V.A.G 1552) and select engine electronics control module with the "Address word" 01. Ignition must be switched on when doing this: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 349 Electronic Power Control (EPC) Página 9 de 13 20-70 Note: The engine control module calculates the angle sender voltage value as a percent of 5 Volts and displays this percentage. (5 volt supply voltage equals 100%). - Depress accelerator pedal slowly until fully depressed and observe percentage figures in display zones 3 and 4: Percentage display in display zone 3 must...
  • Page 350 Electronic Power Control (EPC) Página 10 de 13 20-71 If the displays do not indicate as described: - Check Throttle Position (TP) sensor -G79 Sender -2- for accelerator pedal position voltage supply and wiring connections 20-71 Checking voltage supply and wiring to control module - Remove cover in footwell (driver's side).
  • Page 351 Electronic Power Control (EPC) Página 11 de 13 20-72 - Connect test box VAG 1598/31 to control module wiring harness. Engine control module remains disconnected. - Check wiring for open circuit between test box and connector referring to wiring diagram. Contact 1 and socket 72 Contact 2 and socket 73 Contact 3 and socket 36...
  • Page 352 Electronic Power Control (EPC) Página 12 de 13 20-73 If no wiring malfunction is detected: - Replace TP sensor / Sender for accelerator pedal position Page 20-66 , item - 4 -. - Check Diagnostic Trouble Code (DTC) memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 353 Electronic Power Control (EPC) Página 13 de 13 20-74 Significance of Electronic Power Control (EPC) warning lamp Location of EPC warning lamp When the ignition is switched on the engine control module checks all components which are important for the correct functioning of the electronic power control.
  • Page 354 Exhaust system components, servicing Página 1 de 25 26-1 Exhaust system components, servicing Note: After working on the exhaust system make sure that the system is not under stress, and that it has sufficient clearance to the bodywork. If necessary, loosen double clamp(s) and align muffler and exhaust pipe so that sufficient clearance is maintained to the bodywork and the support elements/mountings are evenly...
  • Page 355 Exhaust system components, servicing Página 2 de 25 26-2 Special tools equipment 3337 Oxygen sensor ring spanner VAG 1331 Torque wrench (5...50 VAG 1332 Torque wrench (40...200 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 356 Exhaust system components, servicing Página 3 de 25 26-3 Exhaust manifold, front exhaust pipe and catalytic converter with attachments Note: Replace self-locking nuts. Components marked with an * are checked by On Board Diagnostic (OBD): Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 357 Exhaust system components, servicing Página 4 de 25 26-4 5 - 13 Nm 6 - 25 Nm 7 - Heat shield 8 - 10 Nm 9 - Coolant pipe Secured exhaust manifold together with heat shield Coolant hose connection diagram Page 19- Connector Black,...
  • Page 358 Exhaust system components, servicing Página 5 de 25 26-5 11 - Heated Oxygen Sensor (HO2S) - G39-*, 50 Nm Remove install with oxygen sensor ring spanner 3337 Grease only threads with G 052 112 A3 hot bolt paste (anti-seize compound). Grease must not get into...
  • Page 359 Exhaust system components, servicing Página 6 de 25 Connector Black, 4-pin Contacts 3 and 4 are gold plated CAUTION! Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 360 Exhaust system components, servicing Página 7 de 25 26-6 Oxygen Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130-*, 50 Nm Remove install with oxygen sensor ring spanner 3337 Grease only threads with G 052 112 A3 hot bolt paste (anti-seize compound).
  • Page 361 Exhaust system components, servicing Página 8 de 25 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group 14 - Front exhaust pipe with catalytic converter Checking catalytic converter Page 26-16 15 - To forward muffler Page 26-8 item 1 CAUTION! Part numbers...
  • Page 362 Exhaust system components, servicing Página 9 de 25 26-7 16 - 5 Nm 17 - Heat shield catalytic converter Securing clamp Replace Slide onto retainer from rear before tightening clamp 19 - 40 Nm Replace 20 - Gasket Replace 2-part http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 363 Exhaust system components, servicing Página 10 de 25 26-8 Muffler with mountings 1 - From catalytic converter 2 - Marking 3 - Flat round head bolt 4 - Double clamp Replace Observe installation position Fig. 1 5 - M8: 25 Nm, M10: 40 Nm Support element/mounting...
  • Page 364 Exhaust system components, servicing Página 11 de 25 26-9 7 - Forward muffler As standard, forward muffler and rear muffler are installed as a single component. In repair cases forward muffler and rear muffler are supplied individually with a double clamp for connecting together.
  • Page 365 Exhaust system components, servicing Página 12 de 25 muffler and rear muffler are supplied individually with a double clamp for connecting together. Separating points Fig. Observe installation position of end pipe Fig. 5 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 366 Exhaust system components, servicing Página 13 de 25 26-10 Support element/mounting 11 - Tunnel bridge With hole to align exhaust system Aligning exhaust system Page 26-14 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 367 Exhaust system components, servicing Página 14 de 25 26-11 Fig. 1 Installation position of double clamp - Position new double clamp, as illustrated, approx. 5 mm from markings -A- and tighten. Tightening torque: 40 Nm Note: Mark -A- is valid for models with a manual or an automatic transmission.
  • Page 368 Exhaust system components, servicing Página 15 de 25 26-12 Fig. 3 Installation position of mounting Angled side on base of mounting (arrow) points forward. Fig. 4 Separating point on exhaust pipe Special tools and equipment Body saw e.g. VAG 1523 - Separate exhaust pipe at right angles at separating point (arrow -2-).
  • Page 369 Exhaust system components, servicing Página 16 de 25 26-13 Fig. 5 Installation position of rear muffler end pipes Work sequence - Align rear muffler so that dimension to body -x- and -y- for end pipes -1- are equal on left and right-hand sides.
  • Page 370 Exhaust system components, servicing Página 17 de 25 26-14 Exhaust system, aligning Special tools and equipment M10x80 hex bolt - Locally manufacture an alignment tool from an M10x80 hex bolt, to dimensions given. Dimension x = 4 mm Dimension Y = 25 mm Work sequence Note: An assistant is required to help in...
  • Page 371 Exhaust system components, servicing Página 18 de 25 26-15 - Slide exhaust system forward until locally manufactured tool can be inserted through rearmost hole in tunnel bridge (arrow). Flattened side of locally manufactured tool faces toward exhaust system hanger pins. - Position new double clamp, as illustrated, approx.
  • Page 372 Exhaust system components, servicing Página 19 de 25 26-16 Catalytic converter, checking Special tools and equipment V.A.G 1551 Scan Tool (or vehicle system tester V.A.G 1552) with cable VAG 1551/3 Note: All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the tester VAS 5051.
  • Page 373 Exhaust system components, servicing Página 20 de 25 26-17 Coolant temperature must be at least 85 C, display group 1, display zone 2. Catalytic converter temperature must be at least 380 C, display group 46, display zone 2. No DTCs may be stored in DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 374 Exhaust system components, servicing Página 21 de 25 26-18 Test sequence - Connect V.A.G 1551 (or V.A.G 1552). Start engine and select "Address word" 01 of engine control module. Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group Indicated on display Rapid data transfer HELP...
  • Page 375 Exhaust system components, servicing Página 22 de 25 26-19 - Change to display group 46 as follows: - Press C key. Indicated on display Basic setting Input display group number XXX - Press keys 0, 4 and 6 for "Display group number 46"...
  • Page 376 Exhaust system components, servicing Página 23 de 25 26-20 - Release brake and accelerator pedals. "Cat B1 OK." appears in display zone 4: - Press key. - Press keys 0 and 6 for function "End output" and confirm entry with Q key. - Switch ignition off.
  • Page 377 Exhaust system components, servicing Página 24 de 25 26-21 - Generate readiness code again if DTC memory has been erased or engine control module disconnected from permanent positive supply: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF, Repair Group If no DTC is stored in DTC memory: - Press keys 0 and 6 for function "End output"...
  • Page 378 Exhaust system components, servicing Página 25 de 25 26-22 Significance of Malfunction Indicator Lamp (MIL) for exhaust emissions If the engine control module detects a malfunction it switches on the Malfunction Indicator Lamp (MIL). Location MIL Note: The MIL can switch on in the continuous or flashing mode.
  • Page 379 Secondary air system Página 1 de 35 26-23 Secondary air system CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
  • Page 380 Secondary air system Página 2 de 35 26-24 Components of the secondary air system, removing and installing Note: Components marked with an * are checked by On Board Diagnostic (OBD): Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s) BDF, Repair Group 01 Components...
  • Page 381 Secondary air system Página 3 de 35 compartment) 1 - Intake manifold 2 - Vacuum actuator variable intake manifold change- over http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 382 Secondary air system Página 4 de 35 26-25 3 - To intake manifold 4 - To fuel pressure regulator 5 - Combi- valve Checking Page 26-41 6 - Gasket Replace 7 - Air channel cylinder head 8 - 8 Nm Ground connection Check...
  • Page 383 Secondary air system Página 5 de 35 26-26 Pressure hose Check seated securely Press together at front release 13 - O-ring Replace damaged 14 - Union 15 - Air cleaner Clean if dirty Retaining clip 17 - Bracket secondary air pump motor Secured to oil...
  • Page 384 Secondary air system Página 6 de 35 26-27 Secondary Injection (AIR) pump motor - V101-** Checking Page 26-38 21 - Intake hose Check secure seating Press together at front release Connector Black, 2-pin intake manifold change- over valve Mark connector component before pulling...
  • Page 385 Secondary air system Página 7 de 35 secondary solenoid valve Mark connector component before pulling connector off. 24 - Intake Manifold Change- Over valve - N156- */** Valve is activated engine control module (pulsed) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 386 Secondary air system Página 8 de 35 26-28 Secondary Injection (AIR) solenoid valve - N112-* Valve is activated engine control module (pulsed) 26 - Vacuum reservoir 27 - Non- return valve Observe installation position White connector faces Secondary injection solenoid valve - N112- /Intake...
  • Page 387 Secondary air system Página 9 de 35 motor http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 388 Secondary air system Página 10 de 35 26-29 Fig. 1 Position of relays in protective housing (on left in engine compartment) 1 - Secondary Air Injection (AIR) pump relay -J299-* 2 - Motronic ECM power supply relay -J271-* Note: If tools are necessary to pull relays or control modules out of the relay plate, first disconnect the battery Ground strap.
  • Page 389 Secondary air system Página 11 de 35 26-30 Safety precautions Observe the following if test and measuring instruments are required during a test drive: Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this location. If test and measuring instruments are operated from the front passenger's seat and the vehicle is involved in an accident, there is a possibility...
  • Page 390 Secondary air system Página 12 de 35 26-31 Secondary air system, checking Special tools and equipment V.A.G 1551 Scan Tool (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3 Note: All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the tester VAS 5051.
  • Page 391 Secondary air system Página 13 de 35 26-32 Main fuses must be OK. Battery voltage must be at least 11.5 V. All electrical consumers, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.

  • Page 392: Functional Check

    Secondary air system Página 14 de 35 26-33 Functional check Test conditions Vacuum lines and hose connections free of leaks. Vacuum lines not blocked or kinked. Selector lever must be in position "P" or "N" on models with an automatic transmission.

  • Page 393: Test Sequence

    Secondary air system Página 15 de 35 26-34 Test sequence - Test drive vehicle. Observe the valid safety precautions when road testing Page 26-30 During the road test the following operating conditions must be fulfilled: The coolant temperature must exceed 85 When the temperature is reached, the operating conditions Idling...

  • Page 394: Engine Control Module

    Secondary air system Página 16 de 35 26-35 - Connect V.A.G 1551 Scan Tool (or V.A.G 1552). Start engine and select "Address word" 01 of engine control module: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s) BDF, Repair Group Indicated on display: Rapid data transfer HELP...
  • Page 395 Secondary air system Página 17 de 35 26-36 Indicated on display Basic setting Input display group number XXX - Press keys 0, 7 and 7 for "Display group number 77" and confirm entry with Q key. Note: The engine must not be loaded during this diagnosis, if this occurs the diagnosis will be aborted and will not start again until the engine is...
  • Page 396 Secondary air system Página 18 de 35 26-37 - Press keys 0 and 6 for function "End output" and confirm entry with Q key. - Switch ignition off. If "Syst.n.OK." appears in display zone 4: - Press key. - Check DTC memory: Repair Manual, 2.8 Liter VR6 4V Fuel Injection &...
  • Page 397 Secondary air system Página 19 de 35 26-38 Secondary Air Injection (AIR) pump motor -V101-, checking Special tools and equipment V.A.G 1551 Scan Tool (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3 Note: All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the tester VAS 5051.
  • Page 398 Secondary air system Página 20 de 35 26-39 Main fuses must be OK. Battery voltage must be at least 11.5 V. All electrical consumers, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 399 Secondary air system Página 21 de 35 26-40 Test sequence - Remove engine cover. - Disconnect pressure hose to combi-valve at coupling (arrow). Note: To release, press buttons together on hose coupling. - Activate Secondary Air Injection (AIR) pump relay -J299- via output Diagnostic Test Mode (DTM): Repair Manual, 2.8 Liter VR6 4V...
  • Page 400 Secondary air system Página 22 de 35 26-41 Combi-valve, checking Special tools and equipment VAG 1390 Hand vacuum pump Test conditions Vacuum lines and hose connections free of leaks. Pressure hose for secondary air injection pump motor not blocked or kinked. Vacuum lines not blocked or kinked.
  • Page 401 Secondary air system Página 23 de 35 26-42 - Remove intake hose between Mass Air Flow (MAF) sensor and throttle valve control module: Repair Manual, 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s) BDF, Repair Group - Pull vacuum hose off Secondary Air Injection (AIR) solenoid valve -N112- and combi-valve (arrow).
  • Page 402 Secondary air system Página 24 de 35 26-43 - Disconnect pressure hose to combi-valve at coupling (arrow) and blow in using light pressure. Combi-valve must be closed. - Operate hand vacuum pump. Combi-valve must open. When the combi-valve does not open or is continuously open: - Replace combi-valve Page 26-...
  • Page 403 Secondary air system Página 25 de 35 26-44 EVAP system, checking using KLI 9210 tester Introduction The KLI 9210 EVAP tester allows testing using nitrogen to pressurize the EVAP system and a smoke generator or ultrasonic tester to locate the source of EVAP system concerns.
  • Page 404 Secondary air system Página 26 de 35 26-45 Calibrating the KLI 9210 tester Determine the vehicle leak threshold: Up to and including M.Y. 1999 leak threshold = 0.040 in. From M.Y. 2000 leak threshold = 0.020 in. - Attach test hose to appropriate pre-set port (black arrows).
  • Page 405 Secondary air system Página 27 de 35 26-46 If no pressure drop is indicated: - Proceed to "Checking Leak Detection Pump V144- for internal leaks". If pressure drop is indicated: - Replace fuel cap and re-test. - Proceed to "Checking Leak Detection Pump V144- for internal leaks".
  • Page 406 Secondary air system Página 28 de 35 26-47 - Start engine. - From VAS 5051 Start-up screen, select "Vehicle self diagnosis". - Select vehicle system "01 - Engine electronics". - Select Diagnosis Function "04 - Basic settings". http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 407 Secondary air system Página 29 de 35 26-48 - Input appropriate display group from table below on keypad. Engine code Display group AEB, AEG, AFP, AHA, APH, ATQ, ATW, AUG, AWD, AWM, AWP, AWV, AWW, BDC, BDF, BEV, BGD, BGJ AVH, AZG, BAP, BBW, - Press "Q"...
  • Page 408 Secondary air system Página 30 de 35 26-49 A similar screen appears, Test is "ON" (indicated by a "1" in position 5, -arrow-). Position 1 -arrow- alternates between "0" and "1" during pump operation. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 409 Secondary air system Página 31 de 35 26-50 If test is OK: Indicated by "1" in position 6 and a "0" in position 8 as shown. LDP has activated and the system is pressurized. - Using a compressed air blow gun, clear area near LDP and LDP filter of any residual smoke.
  • Page 410 Secondary air system Página 32 de 35 26-51 - Make repairs as necessary and check with smoke again. No smoke coming from filter indicates LDP is OK and leak is somewhere else in EVAP system Note: If the KLI 9210 EVAP system tester is connected in "Test"...
  • Page 411 Secondary air system Página 33 de 35 26-52 Note: Fuel system pressurization depends on volume of fuel system and amount of fuel in tank. If fuel system pressurization does not stabilize: - Verify that all fuel system outlets have been sealed before continuing.
  • Page 412 Secondary air system Página 34 de 35 26-53 - Inspect complete EVAP system for escaping smoke. Note: It may be necessary to move, twist, or wiggle EVAP components around to reproduce leak. If leak cannot be found using smoke: - Locate leak with ultrasonic tester. General search: tester only Localized search: tester with extension wand (left)
  • Page 413 Secondary air system Página 35 de 35 26-54 Note: Because leak may be at top of fuel tank, it may not be possible to locate through fuel pump/sending unit access plate. Lower fuel tank if necessary to locate leak. CAUTION! Do not return vehicle to the customer without having performed a proper diagnosis and repair.
  • Page 414 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF Página 1 de 3 Select a topic 01 - On Board Diagnostic (OBD) On Board Diagnostic (OBD) On Board Diagnostic (OBD) features Electronic Power Control (EPC) Warning Light -K132- Malfunction Indicator Light (MIL) -K83- On Board Diagnostic (OBD), technical data VAG 1551 and Motronic Engine Control Module (ECM) -J220-,...
  • Page 415 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF Página 2 de 3 improvement, evaluating Measured value blocks, display groups 120...129 - Communication, evaluating 24 - Multiport Fuel Injection (MFI) Fuel injection system, servicing Component locations overview Fuel injection system, general notes Fuel injection system components, removing and installing Intake manifold, disassembling and assembling Fuel rail, disassembling and assembling...
  • Page 416 2.8 Liter VR6 4V Fuel Injection & Ignition, Engine Code(s): BDF Página 3 de 3 Vehicle Speed Signal, checking A/C compressor signal, checking Signal from Clutch Vacuum Vent Valve Switch -F36-, checking Brake Light Switch -F- and Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection -F47- signal, checking Transmission Range signal, checking Cruise Control System (CCS), checking...
  • Page 417 On Board Diagnostic (OBD) Página 1 de 22 01-1 On Board Diagnostic (OBD) On Board Diagnostic (OBD) features The Motronic Engine Control Module (ECM) -J220- is equipped with a DTC memory. If Diagnostic Trouble Codes (DTCs) occur in the sensors and components being monitored, they will be stored in the DTC memory together with an indication of the type of malfunction.
  • Page 418 On Board Diagnostic (OBD) Página 2 de 22 01-2 The DTC memory must be erased after the malfunction(s) have been repaired Page 01-23 and the readiness code must be regenerated Page 01-149 All Motronic Engine Control Module (ECM) - J220- learned values will be erased when the Motronic Engine Control Module (ECM) -J220- connector is pulled off or the battery is disconnected.
  • Page 419 On Board Diagnostic (OBD) Página 3 de 22 01-3 Electronic Power Control (EPC) Warning Light -K132- "EPC" is the abbreviation for Electronic Power Control. Location of Electronic Power Control (EPC) Warning Light -K132- When the ignition is switched on the Motronic Engine Control Module (ECM) -J220- checks all components which are important for the correct...
  • Page 420 On Board Diagnostic (OBD) Página 4 de 22 01-4 If the Electronic Power Control (EPC) Warning Light -K132- lights up with ignition switched on: - Start engine and run at idle: The Electronic Power Control (EPC) Warning Light -K132- must go out after several seconds. If the Electronic Power Control (EPC) Warning Light -K132- does not go out: - Check DTC memory, repair Diagnostic Trouble...
  • Page 421 On Board Diagnostic (OBD) Página 5 de 22 01-5 Malfunction Indicator Light (MIL) -K83- If the Motronic Engine Control Module (ECM) -J220- detects a malfunction this is indicated by switching the Malfunction Indicator Light (MIL) on. Location of Malfunction Indicator Light (MIL) Note: The Malfunction Indicator Light (MIL)
  • Page 422 On Board Diagnostic (OBD) Página 6 de 22 01-6 Functional check: - Switch on ignition: Malfunction Indicator Light (MIL) must light-up. If the Malfunction Indicator Light (MIL) does not light-up with ignition switched on: - Check instrument cluster and Electronic Power Control (EPC) Warning Light -K132-: Repair Manual, Electrical Equipment On Board Diagnostic (OBD),Repair Group 01...
  • Page 423 On Board Diagnostic (OBD) Página 7 de 22 01-7 On Board Diagnostic (OBD), technical data Control module identification The control module version is displayed when the VAG 1551 scan tool, the vehicle system tester VAG 1552 or the vehicle diagnostic, testing and information system VAS 5051 is connected and Engine Control Module (ECM) selected Page 01-12...
  • Page 424 On Board Diagnostic (OBD) Página 8 de 22 01-8 Engine code Oxygen Sensor control 2 sensors Knock control 2 knock sensors Three Way Catalytic Converter (TWC) Exhaust gas recirculation Charging Secondary air system Electronic Power Control Variable intake manifold Variable valve timing Two independently variable camshafts.
  • Page 425 On Board Diagnostic (OBD) Página 9 de 22 01-9 Functions which can be selected when using the VAG 1551/1552 or VAS 5051 scan tools The prerequisites to select the desired functions can be found in the following table. Function Prerequisite Functions on VAG Engine not running, Engine...
  • Page 426 On Board Diagnostic (OBD) Página 10 de 22 01-10 Selecting functions (mode) via address word 33, CARB / OBD II Function Prerequisite Engine not running, Engine Vehicle Functions on VAG 1551/1552 or on VAS 5051 ignition switched on running at being driven idle Mode...
  • Page 427 On Board Diagnostic (OBD) Página 11 de 22 01-11 Under Mode 5 the static magnitude of the Oxygen Sensor (O2S) (required by the legislator) can be displayed As this magnitude does not have any significance with reference to the Oxygen Sensor (O2S) diagnosis, Mode 5 is of no significance for a VW dealership.
  • Page 428 On Board Diagnostic (OBD) Página 12 de 22 01-12 VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool Note: The vehicle system tester VAG 1552 can be used instead of the VAG 1551 scan tool, however a print-out is not possible.
  • Page 429 On Board Diagnostic (OBD) Página 13 de 22 01-13 Test prerequisites The fuses must be OK. The main fuses must be OK. The battery voltage must be at least 11.5 V. Ground (GND) connection between engine and body must be OK. All electrical devices, e.g.
  • Page 430 On Board Diagnostic (OBD) Página 14 de 22 01-14 Work sequence - Connect VAG 1551 scan tool ((VAG 1552) with cable VAG 1551/3. After the scan tool has been connected, depending upon desired function: - Switch ignition on or Start engine Page 01-9 , Table "Selectable functions".
  • Page 431 On Board Diagnostic (OBD) Página 15 de 22 01-15 - Operate scan tool taking into account the information on display: Indicated on display: VAG SELF-DIAGNOSIS HELP 1 - Rapid data transfer* * Appears alternately 2 - Flash code output* - Operate scan tool, taking into account the information on display: - Press button -1- for "Rapid data transfer".
  • Page 432 On Board Diagnostic (OBD) Página 16 de 22 01-16 Coding 00032 = control module coding, coding variants of Motronic Engine Control Module (ECM) -J220- Page 24-181 WSC 00000 = Workshop code of VAG 1551 with which the last coding was carried out. (If the factory coding has not been changed, WSC 00000 appears) Note:...
  • Page 433 On Board Diagnostic (OBD) Página 17 de 22 01-17 If the coding differs from the vehicle version, then: - Check control module coding Page 24-177 coding Motronic Engine Control Module (ECM) - J220-. - Press -button. Indicated on display: Rapid data transfer HELP Select function XX - See repair procedures for further measures.
  • Page 434 On Board Diagnostic (OBD) Página 18 de 22 01-18 VAS 5051 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and information system VAS 5051 in the operating mode vehicle On Board Diagnosis (OBD):...
  • Page 435 On Board Diagnostic (OBD) Página 19 de 22 01-19 Test prerequisites The fuses must be OK. The main fuses must be OK. The battery voltage must be at least 11.5 V. Ground (GND) connection between engine and body must be OK. All electrical devices, e.g.
  • Page 436 On Board Diagnostic (OBD) Página 20 de 22 01-20 Work sequence - Connect VAS 5051 using VAS 5051/1 or VAS 5051/3 diagnostic adapter cable as follows: - Connect connector of diagnostic adapter cable onto DLC. - Depending upon desired function: Switch ignition on or Start engine Page 01-9 , Table...
  • Page 437 On Board Diagnostic (OBD) Página 21 de 22 01-21 Indicated on display: Select operating mode: - Press button on screen for "Vehicle self-diagnosis". Indicated on display: Select vehicle system: - Press button "01 - Engine electronics" on screen. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 438 On Board Diagnostic (OBD) Página 22 de 22 01-22 The control module identification and coding are shown on the display, e.g.: If the coding differs from the vehicle version, then: - Check control module coding Page 24-177 , Coding Motronic Engine Control Module (ECM) - J220-.
  • Page 439 DTC memory Página 1 de 7 01-23 DTC memory Check DTC memory of all control modules Page 01-27 , Automatic test sequence. DTC memory, checking and erasing Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool (or VAG 1552 vehicle system tester) with VAG 1551/3 adapter cable Note:...
  • Page 440 DTC memory Página 2 de 7 01-24 The main fuses must be OK. The battery voltage must be at least 11.5 V. Ground (GND) connection between engine and body must be OK. All electrical devices, e.g. lights and rear window heating must be turned off.
  • Page 441 DTC memory Página 3 de 7 01-25 - Switch on scan tool printer with the print button. Warning light in button must light Indicated on display: Rapid data transfer HELP Select function XX - Operate scan tool, taking into account information on display: - Press buttons -0- and -2- for function "Check DTC memory"...
  • Page 442 DTC memory Página 4 de 7 01-26 - Press buttons -0- and -5- for the function "Erase DTC memory" and confirm entry with -Q- button. Indicated on display: Rapid data transfer DTC memory is erased! Note: If the ignition is switched off between "Check DTC memory"...
  • Page 443 DTC memory Página 5 de 7 01-27 Automatic test sequence Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool (or vehicle system tester VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and...
  • Page 444 DTC memory Página 6 de 7 01-28 Work sequence - Connect VAG 1551 scan tool (or VAG 1552) using VAG 1551/3 adapter cable. During test and assembly work Diagnostic Trouble Codes (DTCs) can be detected from other control modules like e.g. connector disconnected.
  • Page 445 DTC memory Página 7 de 7 01-29 During the road test the following operating conditions must be fulfilled: The coolant temperature must exceed 85 When the temperature is reached, the operating conditions Idling, Part throttle, Wide open throttle, Overrun must be attained several times.
  • Page 446 DTC table: SAE P0 codes Página 1 de 29 01-30 DTC table: SAE P0 codes Note: The DTC code overview is listed according to SAE or VAG code. Electronic Power Control "EPC" relevant Diagnostic Trouble Codes (DTCs) are indicated additionally by the Electronic Power Control (EPC) Warning Light -K132- in the instrument cluster.
  • Page 447 DTC table: SAE P0 codes Página 2 de 29 01-31 Explanation of SAE Diagnostic Trouble Codes (DTCs): System type: Pxxxx = Diagnostic Trouble Codes (DTCs) for the drive Standardized code: P0xxx = Defined Diagnostic Trouble Codes (DTCs) with standardized DTC text according to SAE P1xxx = Supplementary emissions relevant Diagnostic Trouble Codes (DTCs) provided by manufacturer...
  • Page 448 DTC table: SAE P0 codes Página 3 de 29 Px9xx = Control module, input and output signals http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 449 DTC table: SAE P0 codes Página 4 de 29 01-32 DTCs P0010 to P0704, VAG 16394 to 17088 Fuel and air measurements and supplementary exhaust gas control DTC code DTC text Corrective action P0010 16394 Bank 1 camshaft - Check camshaft timing adjustment valve timing adjustment Page 01-100 , Output Diagnosis Test Mode...
  • Page 450 DTC table: SAE P0 codes Página 5 de 29 01-33 DTC code DTC text Corrective action P0030 16414 Bank 1, sensor 1 - Check Oxygen Sensor (O2S) heating before heating element Three Way Catalytic Converter (TWC) Page circuit 24-38 Open circuit P0031 16415 Bank 1, sensor 1 - Check Oxygen Sensor (O2S) and Oxygen heating element...
  • Page 451 DTC table: SAE P0 codes Página 6 de 29 01-34 Fuel and air measurements DTC code DTC text Corrective action P0101 16485 Mass Air Flow (MAF) - Check Mass Air Flow (MAF) Sensor - Sensor -G70- G70- Page 24-52 Implausible signal P0102 16486 Mass Air Flow (MAF) - Check intake system for leaks Sensor -G70-...
  • Page 452 DTC table: SAE P0 codes Página 7 de 29 01-35 DTC code DTC text Corrective action P0121 16505 Throttle Position (TP) - Check Throttle Valve Control Module - Sensor -G69- J338- Page 24-59 Implausible signal P0122 16506 Throttle Position (TP) Sensor -G69- Signal too low P0123 16507 Throttle Position (TP)
  • Page 453 DTC table: SAE P0 codes Página 8 de 29 01-36 DTC code DTC text Corrective action P0130 16514 Bank 1 sensor 1 - Check Oxygen Sensor (O2S) heating for Oxygen Sensor (O2S) before Three Way Electrical Catalytic Converter (TWC) Page 24-38 malfunction P0131 16515 Bank 1 sensor 1 - Check Oxygen Sensor (O2S) and Oxygen...
  • Page 454 DTC table: SAE P0 codes Página 9 de 29 01-37 DTC code DTC text Corrective action P0136 16520 Bank 1 sensor 2 - Check Oxygen Sensor (O2S) heating for Oxygen Sensor (O2S) after Three Way Electrical Catalytic Converter (TWC) Page 24-45 malfunction P0137 16521 Bank 1 sensor 2 - Check Oxygen Sensor (O2S) and Oxygen...
  • Page 455 DTC table: SAE P0 codes Página 10 de 29 01-38 DTC code DTC text Corrective action P0170 16554 Bank 1 fuel - Check fuel pressure control and holding measuring pressure Page 24-110 system Malfunction - Check fuel injectors Page 24-104 , Checking quantity injected and for leaks - Check fuel pump:...
  • Page 456 DTC table: SAE P0 codes Página 11 de 29 01-39 DTC code DTC text Corrective action P0171 16555 Bank 1 fuel - Check fuel pressure control and holding pressure measuring Page 24-110 system System too lean - Check fuel injectors Page 24-104 - Check fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 457 DTC table: SAE P0 codes Página 12 de 29 01-40 DTC code DTC text Corrective action P0172 16556 Bank 1 fuel - Check fuel pressure control and holding measuring pressure Page 24-110 system System too rich - Check fuel injectors Page 24-104 , Checking quantity injected and for leaks...
  • Page 458 DTC table: SAE P0 codes Página 13 de 29 01-41 Fuel and air measurements DTC code DTC text Corrective action P0201 16585 Cylinder 1 Fuel Injector - - Check fuel injectors Page 24-97 N30- Electrical malfunction P0202 16586 Cylinder 2 Fuel Injector - N31- Electrical malfunction P0203 16587 Cylinder 3 Fuel Injector -...
  • Page 459 DTC table: SAE P0 codes Página 14 de 29 01-42 DTC code DTC text Corrective action P0261 16645 Cylinder 1 Fuel Injector -N30- - Check fuel injectors Page 24-97 Short to Ground (GND) P0262 16646 Cylinder 1 Fuel Injector -N30- Short to positive P0264 16648 Cylinder 2 Fuel Injector -N31- Short to Ground (GND)
  • Page 460 DTC table: SAE P0 codes Página 15 de 29 01-43 DTC code DTC text Corrective action P0270 16654 Cylinder 4 Fuel Injector -N33- Check fuel injectors Page 24-97 Short to Ground (GND) P0271 16655 Cylinder 4 Fuel Injector -N33- Short to positive P0273 16657 Cylinder 5 Fuel Injector -N83- Short to Ground (GND) P0274 16658 Cylinder 5 Fuel Injector -N83-...
  • Page 461 DTC table: SAE P0 codes Página 16 de 29 01-44 Ignition system DTC code DTC text Corrective action P0300 16684 Misfire detected - Check fuel injectors Page 24-97 P0301 16685 Cyl. 1 misfire - Check spark connectors Page 28-15 detected P0302 16686 Cyl.
  • Page 462 DTC table: SAE P0 codes Página 17 de 29 01-45 DTC code DTC text Corrective action P0318 16702 Heavy duty suspension - Check DTC memory ABS control info/ specified engine module: torque from ABS CU, Repair Manual, Brake System On Board Diagnostic (OBD);...
  • Page 463 DTC table: SAE P0 codes Página 18 de 29 01-46 DTC code DTC text Corrective action P0341 16725 Camshaft Position (CMP) - Check Camshaft Position (CMP) Sensor -G40- Sensor -G40- Page 28-16 Implausible signal P0342 16726 Camshaft Position (CMP) Sensor -G40- Signal too low P0343 16727 Camshaft Position (CMP) Sensor -G40-...
  • Page 464 DTC table: SAE P0 codes Página 19 de 29 01-47 Supplementary exhaust gas control DTC code DTC text Corrective action P0411 16795 Secondary air - Check Secondary Air Injection (AIR) Pump Motor: system Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 465 DTC table: SAE P0 codes Página 20 de 29 01-48 DTC code DTC text Corrective action P0412 16796 Secondary Air Injection - Check Secondary Air Injection (AIR) (AIR) Solenoid Valve - Solenoid Valve -N112-- Page 01-100 N112- Output Diagnosis Test Mode (DTM) Electrical malfunction P0413 16797 Secondary Air Injection (AIR) Solenoid Valve -...
  • Page 466 DTC table: SAE P0 codes Página 21 de 29 01-49 DTC code DTC text Corrective action P0420 16804 Bank 1 Three Way - Check Oxygen Sensor (O2S) and Oxygen Catalytic Converter Sensor (O2S) control before Three Way (TWC) system Catalytic Converter (TWC) Page 24-131 Efficiency too low - Check Oxygen Sensor (O2S) and Oxygen...
  • Page 467 DTC table: SAE P0 codes Página 22 de 29 01-50 DTC code DTC text Corrective action P0441 16825 Tank - Check Evaporative Emission (EVAP) Canister ventilation Purge RegulatorValve -N80- Page 01-100 system Output Diagnosis Test Mode (DTM) Flow rate faulty - Check Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 468 DTC table: SAE P0 codes Página 23 de 29 01-51 DTC code DTC text Corrective action P0444 16828 Evaporative Emission - Check Evaporative Emission (EVAP) (EVAP) Canister Purge Canister Purge RegulatorValve -N80- Regulator Valve -N80- Page 01-100 , Output Diagnosis Test Mode (DTM) Open circuit P0445 16829 Evaporative Emission...
  • Page 469 DTC table: SAE P0 codes Página 24 de 29 01-52 Speed and idling control DTC code DTC text Corrective action P0501 16885 Vehicle speed - Check speed signal Page 24-188 signal Implausible signal P0506 16890 Idle speed control - Check throttle valve control module Page 24-59 Revs below...
  • Page 470 DTC table: SAE P0 codes Página 25 de 29 01-53 DTC code DTC text Corrective action P0560 16944 Voltage supply - Check voltage supply Page 24-163 Implausible signal P0562 16946 Voltage supply too - Procedure after interrupting voltage supply Page 24-170 P0563 16947 Voltage supply too high P0568 16952 Cruise control system...
  • Page 471 DTC table: SAE P0 codes Página 26 de 29 01-54 Control module and output signals DTC code DTC text Corrective action P0600 16984 Drive train Can-bus - Check Can-bus matching resistor Page 24-223 Message missing P0601 16985 Control module faulty - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173...
  • Page 472 DTC table: SAE P0 codes Página 27 de 29 01-55 DTC code DTC text Corrective action P0638 17022 Throttle Valve - Check Throttle Valve Control Module Page Control Module - 24-59 J338- Implausible signal - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- to throttle valve control module Page 24-182...
  • Page 473 DTC table: SAE P0 codes Página 28 de 29 01-56 DTC code DTC text Corrective action P0650 17034 Malfunction Indicator Lamp - Check instrument cluster: (MIL) -K83- Repair Manual, Electrical Equipment On Board Diagnostic Electrical malfunction (OBD), Repair Group 01 P0685 17069 Motronic Engine Control - Check voltage supply Page 24-...
  • Page 474 DTC table: SAE P0 codes Página 29 de 29 01-57 Transmission DTC code DTC text Corrective action P0704 17088 Clutch Vacuum Vent - Check signal from Clutch Vacuum Vent Valve Switch -F36- Valve Switch -F36- Page 24-199 Implausible signal http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 475 DTC table: SAE P1 codes Página 1 de 41 01-58 DTC table: SAE P1 codes DTCs P1047 to P1912, VAG 17455 to 18322 Note: The DTC code overview is listed according to SAE or VAG code. Erase DTC memory after repairing malfunction Page 01-23 and generate readiness code again...
  • Page 476 DTC table: SAE P1 codes Página 2 de 41 01-59 Fuel and air measurements DTC code DTC text Corrective action P1102 17510 Bank 1, sensor 1 - Check Oxygen Sensor (O2S) heating for heating element Oxygen Sensor (O2S) before Three Way circuit Catalytic Converter (TWC) Page 24-38...
  • Page 477 DTC table: SAE P1 codes Página 3 de 41 01-60 DTC code DTC text Corrective action P1113 17521 Bank 1, sensor 1 - Check Oxygen Sensor (O2S) heating for Oxygen Sensor (O2S) before Three Way Internal resistance Catalytic Converter (TWC) Page 24-38 too high P1114 17522 Bank 1 sensor 2...
  • Page 478 DTC table: SAE P1 codes Página 4 de 41 01-61 DTC code DTC text Corrective action P1127 17535 Bank 1, mixture - Check fuel pressure control and holding adaption (mult.) pressure Page 24-110 System too rich - Check fuel injectors Page 24-104 - Check Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-:...
  • Page 479 DTC table: SAE P1 codes Página 5 de 41 01-62 DTC code DTC text Corrective action P1128 17536 Bank 1, mixture - Check fuel pressure control and holding adaption (mult.) pressure Page 24-110 System too lean - Check fuel injectors Page 24-104 - Check fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 480 DTC table: SAE P1 codes Página 6 de 41 01-63 DTC code DTC text Corrective action P1136 17544 Bank 1, mixture - Check fuel pressure control and holding adaption (add.), System pressure Page 24-110 too lean - Check fuel injectors Page 24-104 - Check fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 481 DTC table: SAE P1 codes Página 7 de 41 01-64 DTC code DTC text Corrective action P1137 17545 Bank 1, mixture - Check fuel pressure control and holding adaption (add.), pressure Page 24-110 System too rich - Check fuel injectors Page 24-104 - Check Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-:...
  • Page 482 DTC table: SAE P1 codes Página 8 de 41 01-65 DTC code DTC text Corrective action P1141 17549 Load determination - Check Mass Air Flow (MAF) Sensor -G70- Page 24-52 Implausible value P1142 17550 Load determination - Check intake system for leaks Page 24- Limit not reached P1143 17551 Load determination...
  • Page 483 DTC table: SAE P1 codes Página 9 de 41 01-66 DTC code DTC text Corrective action P1151 17559 Bank 1, mixture - Check fuel pressure control and holding adaption region 1 pressure Page 24-110 Below lean limit - Check fuel injectors Page 24-104 - Check fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 484 DTC table: SAE P1 codes Página 10 de 41 01-67 DTC code DTC text Corrective action P1152 17560 Bank 1, mixture - Check fuel injectors Page 24-104 adaption region 2, Below lean limit - Check fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 485 DTC table: SAE P1 codes Página 11 de 41 01-68 DTC code DTC text Corrective action P1165 17573 Bank 1, mixture - Check fuel pressure control and holding adaption region 1 pressure Page 24-110 Rich limit exceeded - Check fuel injectors Page 24-104 - Check Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-:...
  • Page 486 DTC table: SAE P1 codes Página 12 de 41 01-69 DTC code DTC text Corrective action P1171 17579 Angle sensor -2- for throttle - Check Throttle Valve Control drive -G188- Module -J338- Page 24-59 Implausible signal P1172 17580 Angle sensor -2- for throttle drive -G188- Signal too low P1173 17581 Angle sensor -2- for throttle...
  • Page 487 DTC table: SAE P1 codes Página 13 de 41 01-70 DTC code DTC text Corrective action P1178 17586 Linear Oxygen Sensor - Check Oxygen Sensor (O2S) and Oxygen (O2S) / pump current Sensor (O2S) control before Three Way Catalytic Converter (TWC) Page 24-131 Open circuit P1179 17587 Linear Oxygen Sensor...
  • Page 488 DTC table: SAE P1 codes Página 14 de 41 (O2S) / common Ground (GND) Short to positive http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 489 DTC table: SAE P1 codes Página 15 de 41 01-71 DTC code DTC text Corrective action P1196 17604 Bank 1 sensor 1, - Check Oxygen Sensor (O2S) heating for heater element Oxygen Sensor (O2S) before Three Way circuit Catalytic Converter (TWC) Page 24-38 Electrical malfunction...
  • Page 490 DTC table: SAE P1 codes Página 16 de 41 01-72 Fuel and air measurements DTC code DTC text Corrective action P1250 17658 Fuel level too Fuel level in fuel tank less than 5 liter: - Fill fuel tank - Check signal from fuel gauge sensor: Repair Manual, Electrical Equipment On Board Diagnostic (OBD), Repair Group 01 P1296 17704 Malfunction in...
  • Page 491 DTC table: SAE P1 codes Página 17 de 41 01-73 Ignition system DTC code DTC text Corrective action P1325 17733 Knock control - Check knock sensors Page 28-30 cyl. 1 control limit reached P1326 17734 Knock control - Repair abnormal engine running noises cyl.
  • Page 492 DTC table: SAE P1 codes Página 18 de 41 01-74 DTC code DTC text Corrective action P1335 17743 Engine torque monitor 2 - Check Intake Air Temperature (IAT) sensor -G42- Page 24-81 Control limit exceeded P1336 17744 Engine torque monitor - Check Mass Air Flow (MAF) Sensor -G70- Page 24-52...
  • Page 493 DTC table: SAE P1 codes Página 19 de 41 01-75 DTC code DTC text Corrective action P1355 17763 Ignition timing cyl. - Check ignition coils with power output stage Page 28-23 Open circuit P1356 17764 Ignition timing cyl. Short to positive P1357 17765 Ignition timing cyl.
  • Page 494 DTC table: SAE P1 codes Página 20 de 41 01-76 DTC code DTC text Corrective action P1364 17772 Ignition timing cyl. - Check ignition coils with power output stage Page 28-23 Open circuit P1365 17773 Ignition timing cyl. Short to positive P1366 17774 Ignition timing cyl.
  • Page 495 DTC table: SAE P1 codes Página 21 de 41 01-77 DTC code DTC text Corrective action P1385 17793 Control module faulty - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 P1386 17794 Control module faulty P1387 17795 Control module faulty P1388 17796 Control module faulty P1391 17799 Bank 2, Camshaft Position - Check Camshaft Position (CMP)
  • Page 496 DTC table: SAE P1 codes Página 22 de 41 01-78 Supplementary exhaust gas control DTC code DTC text Corrective action P1409 17817 Evaporative Emission - Check Evaporative Emission (EVAP) (EVAP) Canister Purge Canister Purge RegulatorValve -N80- Regulator Valve -N80- Page 01-100 , Output Diagnosis Test Mode (DTM) Electrical malfunction...
  • Page 497 DTC table: SAE P1 codes Página 23 de 41 01-79 DTC code DTC text Corrective action P1422 17830 Secondary Air Injection (AIR) Solenoid Valve - N112- Short to positive P1424 17832 Bank 1, secondary air - Check secondary air system: system Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 498 DTC table: SAE P1 codes Página 24 de 41 01-80 DTC code DTC text Corrective action P1427 17835 Brake System - Check Brake System Vacuum Pump Vacuum Pump Page 01-100 , Output Diagnosis Test Mode activation (DTM) Short to positive P1428 17836 Brake System Vacuum Pump activation...
  • Page 499 DTC table: SAE P1 codes Página 25 de 41 01-81 DTC code DTC text Corrective action P1432 17840 Secondary Air Injection - Check Secondary Air Injection (AIR) (AIR) Solenoid Valve - Solenoid Valve -N112- Page 01-100 N112- Output Diagnosis Test Mode (DTM) Open circuit P1433 17841 Secondary Air Injection - Check Secondary Air Injection (AIR)
  • Page 500 DTC table: SAE P1 codes Página 26 de 41 01-82 DTC code DTC text Corrective action P1470 17878 Leak Detection Pump (LDP) - Check Leak detection pump (LDP) - -V144- V144- Page 01-100 , Output Diagnosis Test Mode (DTM) Electrical malfunction P1471 17879 Leak Detection Pump (LDP) -V144- Short to positive...
  • Page 501 DTC table: SAE P1 codes Página 27 de 41 01-83 Speed and idling control DTC code DTC text Corrective action P1500 17908 Fuel Pump (FP) Relay - Check Fuel Pump (FP) Relay -J17-: -J17- Electrical Wiring Diagrams, Troubleshooting & Component Locations Electrical malfunction P1501 17909 Fuel Pump (FP) Relay -J17-...
  • Page 502 DTC table: SAE P1 codes Página 28 de 41 01-84 DTC code DTC text Corrective action P1517 17925 Motronic Engine Control - Check voltage supply Page 24- Module (ECM) Power Supply Relay -J271- Electrical malfunction - Procedure after interrupting voltage supply Page 24-170 - Check Motronic Engine Control...
  • Page 503 DTC table: SAE P1 codes Página 29 de 41 01-85 DTC code DTC text Corrective action P1523 17931 Crash signal from airbag - Check and erase DTC memory control module, Page 01-23 Implausible signal - Check airbag system: Repair Manual, Body On Board Diagnostic (OBD);...
  • Page 504 DTC table: SAE P1 codes Página 30 de 41 01-86 DTC code DTC text Corrective action P1539 17947 Clutch Vacuum Vent - Check signal from Clutch Vacuum Vent Valve Switch -F36- Valve Switch -F36- Page 24-199 Implausible signal P1541 17949 Fuel Pump (FP) Relay - - Check fuel pump relay: J17- Electrical Wiring Diagrams,...
  • Page 505 DTC table: SAE P1 codes Página 31 de 41 01-87 DTC code DTC text Corrective action P1558 17966 Throttle valve drive - - Check Throttle Valve Control Module -J338- G186- Page 24-59 Electrical malfunction P1559 17967 Throttle Valve - Erase learned values and adapt Motronic Control Module - Engine Control Module (ECM) -J220- to J338-...
  • Page 506 DTC table: SAE P1 codes Página 32 de 41 01-88 DTC code DTC text Corrective action P1569 17977 CCS switch -E45- - Check cruise control system (CCS) Page 24-218 Implausible signal P1570 17978 Motronic Engine - Adapt (match) Motronic Engine Control Control Module Module (ECM) -J220- to electronic (ECM) -J220-...
  • Page 507 DTC table: SAE P1 codes Página 33 de 41 01-89 Control module and output signals DTC code DTC text Corrective action P1602 18010 Voltage supply terminal 30 - Check voltage supply Page 24- Voltage supply too low - Procedure after interrupting voltage supply Page 24-170 P1603 18011 Motronic Engine Control...
  • Page 508 DTC table: SAE P1 codes Página 34 de 41 01-90 DTC code DTC text Corrective action P1612 18020 Motronic Engine Control - Code Motronic Engine Control Module (ECM) -J220- Module (ECM) -J220- Page 24- Incorrect coding P1624 18032 Request for Malfunction - Check DTC memories of all Indicator Light (MIL) on control modules and erase...
  • Page 509 DTC table: SAE P1 codes Página 35 de 41 01-91 DTC code DTC text Corrective action P1630 18038 Throttle Position (TP) - Check Throttle Position (TP) Sensor - Sensor -G79- G79-: Repair Manual, 2.8 Liter VR6 4V Signal too low Engine Mechanical, Engine Code(s): BDF;...
  • Page 510 DTC table: SAE P1 codes Página 36 de 41 01-92 DTC code DTC text Corrective action P1636 18044 Drive train Can-bus - Check Can-bus matching resistor Page 24-223 No message from airbag control module - Check airbag system: Repair Manual, Body On Board Diagnostic (OBD);...
  • Page 511 DTC table: SAE P1 codes Página 37 de 41 01-93 DTC code DTC text Corrective action P1648 18056 Drive train Can-bus - Check Can-bus matching resistor Page faulty 24-223 P1649 18057 Drive train Can-bus - Check Can-bus matching resistor Page 24-223 No message from ABS control module...
  • Page 512 DTC table: SAE P1 codes Página 38 de 41 01-94 DTC code DTC text Corrective action P1654 18062 Please read DTC memory - Check instrument cluster: of instrument cluster Repair Manual, Electrical Equipment On Board Diagnostic (OBD), Repair Group 01 P1677 18085 Electronic Power Control - Check Can-bus matching resistor (EPC) Warning Light -...
  • Page 513 DTC table: SAE P1 codes Página 39 de 41 01-95 DTC code DTC text Corrective action P1682 18090 Drive train Can-bus - Check Can-bus matching resistor Page 24-223 Implausible message from ABS control module - Check ABS control module DTC memory: Repair Manual, Brake System On Board Diagnostic (OBD);...
  • Page 514 DTC table: SAE P1 codes Página 40 de 41 01-96 DTC code DTC text Corrective action P1691 18099 Malfunction Indicator Lamp - Check Can-bus matching resistor (MIL) -K83- Page 24-223 Open circuit P1692 18100 Malfunction Indicator Lamp - Check instrument cluster and (MIL) -K83- Electronic Power Control (EPC) Warning Light -K132-:...
  • Page 515 DTC table: SAE P1 codes Página 41 de 41 01-97 control module, input and output signals DTC code DTC text Corrective action P1912 18320 Brake Booster Pressure - Check Brake Booster Pressure Sensor - Sensor -G294- G294-: Repair Manual, Brake System On Board Short to positive / Open Diagnostic (OBD);...
  • Page 516 DTC table: SAE P2 codes Página 1 de 1 01-98 DTC table: SAE P2 codes DTCs P2101 to P2138, VAG 18533 to 18570 Note: The DTC code overview is listed according to SAE or VAG code. Erase DTC memory after repairing malfunction Page 01-23 and generate readiness code again...
  • Page 517 DTC table: SAE P3 codes Página 1 de 1 01-99 DTC table: SAE P3 codes DTCs P3211 to P3266, VAG 19667 to 19722 Note: The DTC code overview is listed according to SAE or VAG code. Erase DTC memory after repairing malfunction Page 01-23 and generate readiness code again...
  • Page 518 Output Diagnosis Test Mode (DTM) Página 1 de 45 01-100 Output Diagnosis Test Mode (DTM) Output Diagnosis Test Mode (DTM), performing The Output Diagnosis Test Mode (DTM) activates the following components in the stated sequence: Component Appears on display 1. Evaporative Emission (EVAP) Canister Fuel tank breather valve -N80- Purge RegulatorValve -N80- 2.
  • Page 519 Output Diagnosis Test Mode (DTM) Página 2 de 45 01-101 Component Appears on display 13. Cylinder 2 Fuel Injector -N31- Injector Cyl. 2 -N31- 14. Cylinder 4 Fuel Injector -N33- Injector Cyl. 4 -N33- The VAG 1551 scan tool or VAG 1552 display will show "17457 / Literature. The VAG 1551 scan tool or VAG 1552 display will show "17836 / Literature.
  • Page 520 Output Diagnosis Test Mode (DTM) Página 3 de 45 01-102 Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool (or vehicle system tester VAG 1552) with VAG 1551/3 Adapter cable adapter Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and...
  • Page 521 Output Diagnosis Test Mode (DTM) Página 4 de 45 01-103 Test prerequisites The fuses must be OK. The main fuses must be OK. The battery voltage must be at least 11.5 V. Ground (GND) connection between engine and body must be OK.
  • Page 522 Output Diagnosis Test Mode (DTM) Página 5 de 45 01-104 Fuel Pump (FP) relay -J17- must be OK, checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations Motronic Engine Control Module (ECM) Power Supply Relay -J271- must be OK., checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations Ignition switched on, engine not running.
  • Page 523 Output Diagnosis Test Mode (DTM) Página 6 de 45 01-105 The Output Diagnostic Test elements are checked by hearing or by feeling. The Output Diagnosis Test Mode (DTM) will be aborted after 10 minutes. Run engine briefly first if there is a requirement to repeat Output Diagnosis Test Mode (DTM).
  • Page 524 Output Diagnosis Test Mode (DTM) Página 7 de 45 01-106 1. Activating Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-: - Confirm input with -Q- button. Indicated on display: Output Diagnosis Test Mode Fuel Evaporative Emission (EVAP) Canister Purge Regulator Valve The Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- must...
  • Page 525 Output Diagnosis Test Mode (DTM) Página 8 de 45 01-107 If the solenoid valve does not click: - Disconnect 2-pin connector from Evaporative Emission (EVAP) Canister Purge Regulator Valve - N80- (arrow). - Connect LED test light VAG 1527 to disconnected connector using adapter cables from VAG 1594.
  • Page 526 Output Diagnosis Test Mode (DTM) Página 9 de 45 01-108 Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Replace Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23...
  • Page 527 Output Diagnosis Test Mode (DTM) Página 10 de 45 01-109 - Connect test box VAG 1598/31 to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wire for open circuit between test box socket 64 and 2-pin connector terminal 2 referring to Electrical Wiring Diagrams.
  • Page 528 Output Diagnosis Test Mode (DTM) Página 11 de 45 01-110 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- again Page 24-182 - Read readiness code...
  • Page 529 Output Diagnosis Test Mode (DTM) Página 12 de 45 01-111 If the valve does not click: - Disconnect 2-pin connector from Secondary Air Injection (AIR) Solenoid Valve (arrow). - Connect LED test light VAG 1527 to disconnected connector using adapter cables from VAG 1594. LED must flash (bright/darker) LED flashes: - Press -C- button to abort output...
  • Page 530 Output Diagnosis Test Mode (DTM) Página 13 de 45 01-112 Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Replace Secondary Air Injection (AIR) Solenoid Valve -N112-: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 531 Output Diagnosis Test Mode (DTM) Página 14 de 45 01-113 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wire for open circuit between test box socket 44 and 2-pin connector terminal 2 referring to Electrical Wiring Diagrams.
  • Page 532 Output Diagnosis Test Mode (DTM) Página 15 de 45 01-114 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- again Page 24-182 - Read readiness code...
  • Page 533 Output Diagnosis Test Mode (DTM) Página 16 de 45 01-115 - Disconnect 2-pin connector from Secondary Air Injection (AIR) Pump Motor (arrow). - Connect LED test light VAG 1527 to disconnected connector using adapter cables from VAG 1594. LED must flash http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=...
  • Page 534 Output Diagnosis Test Mode (DTM) Página 17 de 45 01-116 LED flashes: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Replace Secondary Air Injection (AIR) Pump Motor -V101-: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 535 Output Diagnosis Test Mode (DTM) Página 18 de 45 01-117 - Check wire for open circuit between Secondary Air Injection (AIR) pump motor -V101- terminal 1 and body Ground (GND). Wire resistance: max. 1.5 If no electrical or wiring concerns are found: - Pull Secondary Air Injection (AIR) Pump Relay -1- out of relay...
  • Page 536 Output Diagnosis Test Mode (DTM) Página 19 de 45 01-118 - Check wiring for open circuit between connector terminal 2 on Secondary Air Injection (AIR) Pump Motor and terminal 2 on relay plate. - Wire resistance: max. 1.5 If no electrical or wiring concerns are found: - Check wire for open circuit between terminal 1 of relay plate...
  • Page 537 Output Diagnosis Test Mode (DTM) Página 20 de 45 01-119 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 If the LED does not flash and the Secondary Air Injection (AIR) Pump Relay does not...
  • Page 538 Output Diagnosis Test Mode (DTM) Página 21 de 45 01-120 - Connect LED test light VAG 1527 to terminals 2 and 4 on relay plate using adapter cables from VAG 1594. - Initiate output Diagnosis Test Mode (DTM) again and activate Secondary Air Injection (AIR) pump relay -J299-.
  • Page 539 Output Diagnosis Test Mode (DTM) Página 22 de 45 01-121 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 LED does not flash: - Press -C- button to abort output Diagnosis Test...
  • Page 540 Output Diagnosis Test Mode (DTM) Página 23 de 45 01-122 LED does not light-up: - Check wire for open circuit between terminal 1 of relay plate and fuel pump relay -J17- referring to Electrical Wiring Diagrams. Wire resistance: max. 1.5 LED lights up: - Remove wiper arms and cowl panel:...
  • Page 541 Output Diagnosis Test Mode (DTM) Página 24 de 45 01-123 - Check wire for open circuit between test box socket 46 and terminal 4 on relay plate referring to Electrical Wiring Diagrams. Wire resistance: max. 1.5 If no electrical or wiring concerns are found: - Replace Motronic Engine Control Module (ECM) -J220-...
  • Page 542 Output Diagnosis Test Mode (DTM) Página 25 de 45 01-124 4. Activating Intake Manifold Change-Over Valve -N156-: - Press button. Indicated on display: Output Diagnosis Test Mode Intake Manifold Change-Over Valve -N156- The Intake Manifold Change-Over Valve must click until the next final control element is activated by pressing button.
  • Page 543 Output Diagnosis Test Mode (DTM) Página 26 de 45 01-125 - Connect LED test light VAG 1527 to detached connector using adapter cables from VAG 1594. LED must flash (bright/darker) LED flashes: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition.
  • Page 544 Output Diagnosis Test Mode (DTM) Página 27 de 45 01-126 LED does not flash: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment;...
  • Page 545 Output Diagnosis Test Mode (DTM) Página 28 de 45 01-127 - Check wire for open circuit between test box socket 121 and 2-pin connector terminal 2 referring to Electrical Wiring Diagrams. Wire resistance: max. 1.5 - Additionally check wire for short to battery positive and Ground (GND).
  • Page 546 Output Diagnosis Test Mode (DTM) Página 29 de 45 01-128 5. Activating Valve -1- for camshaft adjustment -N205-: - Press -button. Indicated on display: Output Diagnosis Test Mode Valve -1- for camshaft adjustment -N205- The Valve -1- for camshaft adjustment must click until the next final control element is activated by pressing button.
  • Page 547 Output Diagnosis Test Mode (DTM) Página 30 de 45 01-129 - Connect LED test light VAG 1527 to disconneced connector using adapter cables from VAG 1594. LED must flash (bright/darker) LED flashes: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition.
  • Page 548 Output Diagnosis Test Mode (DTM) Página 31 de 45 01-130 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 LED does not flash: - Press -C- button to abort output Diagnosis Test...
  • Page 549 Output Diagnosis Test Mode (DTM) Página 32 de 45 01-131 - Check wire for open circuit between test box socket 115 and 2-pin connector terminal 2 referring to Electrical Wiring Diagrams. Wire resistance: max. 1.5 - Additionally check wire for short to battery positive and Ground (GND).
  • Page 550 Output Diagnosis Test Mode (DTM) Página 33 de 45 01-132 6. Activating Leak detection pump (LDP) -V144-: - Press button. Indicated on display: Output Diagnosis Test Mode Leak Detection Pump tank ventilation system The LDP must click, at intervals, until the next final control element is activated by pressing button.
  • Page 551 Output Diagnosis Test Mode (DTM) Página 34 de 45 01-133 - Connect LED test light VAG 1527 terminals 2 and 3 of detached connector using adapter cables from VAG 1594. LED must flash (bright/darker) LED flashes: - Press -C- button to abort output Diagnosis Test Mode (DTM).
  • Page 552 Output Diagnosis Test Mode (DTM) Página 35 de 45 01-134 LED does not flash: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment;...
  • Page 553 Output Diagnosis Test Mode (DTM) Página 36 de 45 01-135 - Check wiring for open circuit between test box and 3-pin connector referring to Electrical Wiring Diagrams Terminal 1 and socket 80 Terminal 2 and socket 25 Wire resistance: max. 1.5 - Additionally check wire for short to battery positive and Ground (GND).
  • Page 554 Output Diagnosis Test Mode (DTM) Página 37 de 45 01-136 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 7.
  • Page 555 Output Diagnosis Test Mode (DTM) Página 38 de 45 01-137 If the valve does not click: - Disconnect 2-pin connector from Camshaft Adjustment Valve 1 (exhaust) -N318- -2-. Note: Mark connector and component before pulling connector off. - Connect LED test light VAG 1527 to disconnected connector using adapter cables from VAG 1594.
  • Page 556 Output Diagnosis Test Mode (DTM) Página 39 de 45 01-138 Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition. - Replace engine control housing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 15, Valve train, servicing Note: The control housing is only replaced...
  • Page 557 Output Diagnosis Test Mode (DTM) Página 40 de 45 01-139 - Connect test box VAG 1598/31 to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wire for open circuit between test box socket 120 and 2-pin connector terminal 2 referring to Electrical Wiring Diagrams.
  • Page 558 Output Diagnosis Test Mode (DTM) Página 41 de 45 01-140 - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing.
  • Page 559 Output Diagnosis Test Mode (DTM) Página 42 de 45 01-141 If the Brake System Vacuum Pump -V192- does not run: - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition.
  • Page 560 Output Diagnosis Test Mode (DTM) Página 43 de 45 01-142 9...14. Activating fuel injectors (- N30-... -N33-, -N83- and -N84-): - Press button. Indicated on display: Output Diagnosis Test Mode Cylinder 1 Fuel Injector -N30- - Press button again so that fuel injector is actuated five times.
  • Page 561 Output Diagnosis Test Mode (DTM) Página 44 de 45 01-143 If one of the fuel injectors is not activated (does not click): - Press -C- button to abort output Diagnosis Test Mode (DTM). Indicated on display: Output Diagnosis Test Mode was aborted - Switch off ignition.
  • Page 562 Output Diagnosis Test Mode (DTM) Página 45 de 45 01-144 - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 563 Readiness code Página 1 de 37 01-145 Readiness code Function The readiness code is an 8-digit number code which displays the status of the emission relevant diagnosis. When the diagnosis for a system (e.g. secondary air system) has been successfully completed, the corresponding position in the number code will change from 1 to 0.
  • Page 564 Readiness code Página 2 de 37 01-146 Read readiness code Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 Scan tool (or VAG 1552 vehicle system tester) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and...
  • Page 565 Readiness code Página 3 de 37 01-147 Must appear on display when all diagnosis functions have been successfully completed: Indicated on display: Readiness code 00000000 - Test complete - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
  • Page 566 Readiness code Página 4 de 37 01-148 Significance of figures in 8 digit number block, display zone 1 - Readiness code The readiness code is generated only when all display zones show 0 1 2 3 4 5 6 7 8 Diagnostic function 0 Three Way Catalytic Converter (TWC) Three Way Catalytic Converter (TWC) heating (currently no...
  • Page 567 Readiness code Página 5 de 37 01-149 Generating readiness code Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool (or VAG 1552) with VAG 1551/3 Adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and information system VAS 5051.
  • Page 568 Readiness code Página 6 de 37 01-150 The main fuses must be OK. The battery voltage must be at least 11.5 V. If the vehicle is equipped with air conditioning, this must be switched off. Selector lever must be in position "P"...
  • Page 569 Readiness code Página 7 de 37 01-151 Work sequence - Connect VAG 1551 scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with the "Address word" 01. (Connecting scan tool and selecting Engine Control Module (ECM) Page 01-12 Work step 1: Check DTC memory...
  • Page 570 Readiness code Página 8 de 37 01-152 Repair Diagnostic Trouble Codes (DTCs) printed out using DTC table: SAE P0 codes Page 01- SAE P1 codes Page 01- SAE P2 codes Page 01- SAE P3 codes Page 01- If no DTC is stored: - Press button.
  • Page 571 Readiness code Página 9 de 37 01-153 Note: If the ignition is switched off between "Check DTC memory" and "Erase DTC memory" the DTC memory will not be erased. - Press button. Work step 3: Adjust the Throttle Valve Control Module -J338- to the Motronic Engine Control Module (ECM) -J220- Indicated on display:...
  • Page 572 Readiness code Página 10 de 37 01-154 - Terminate engine basic setting at earliest after 30 seconds by pressing button. If the display does not indicate as described: - Check Throttle Valve Control Module -J338- Page 24-59 If the display indicates as described: - Start engine and run at idle.
  • Page 573 Readiness code Página 11 de 37 01-155 - Read Engine Coolant Temperature value in display zone 3. Specification: 85 to 110 C - Read Intake Air Temperature value in display zone 4. Specification: Ambient temperature less than 80 If the specifications are obtained: - Press button.
  • Page 574 Readiness code Página 12 de 37 01-156 Indicated on display: (1 to 4 System in basic setting 71 display zones) If "Reed op." appears in display zone - Open fuel tank filler cap briefly to release pressure in fuel tank. This will close reed terminal.
  • Page 575 Readiness code Página 13 de 37 01-157 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the...
  • Page 576 Readiness code Página 14 de 37 01-158 - Press buttons -0-, -3- and -0- for "Display group number 30" and confirm entry with -Q- button. Indicated on display: (1 to 2 display zones) Read measured value block 30 - Check Oxygen Sensor (O2S) control status before Three Way Catalytic Converter (TWC) (display zone 1): Specification: 111...
  • Page 577 Readiness code Página 15 de 37 01-159 Work step 7: Oxygen Sensor (O2S) aging diagnosis of Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC) Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -4- for function "Initiate basic setting"...
  • Page 578 Readiness code Página 16 de 37 01-160 Note: This process can take approx. 90 seconds. - Depress brake pedal and accelerator down until display zone 4 displays specification "B1-P1 OK.". - Release brake and accelerator pedals. If "B1 P1 n.OK." appears in display zone 4: - Press button.
  • Page 579 Readiness code Página 17 de 37 01-161 Work step 8: Fuel supply system diagnosis (part load) Indicated on display: Basic setting Input display group number XXX - Press buttons -2-, -1- and -6- for "Display group number 216" and confirm entry with -Q- button. Indicated on display: (1 to 4 System in basic setting 216 display zones)
  • Page 580 Readiness code Página 18 de 37 01-162 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the...
  • Page 581 Readiness code Página 19 de 37 01-163 - Check Oxygen Sensor (O2S) control status after Three Way Catalytic Converter (TWC) (display zone 2): Specification: 111 Significance of figures in 3 digit number block Page 01-217 Note: The bits in display zone 2 will not be set to 1 until the Three Way Catalytic Converter (TWC) temperature rises above 380 C ( display...
  • Page 582 Readiness code Página 20 de 37 01-164 Indicated on display: Basic setting Input display group number XXX - Press buttons -0-, -4- and -3- for "Display group number 43" and confirm entry with -Q- button. Indicated on display: (1 to 4 System in basic setting 43 display zones) - Depress brake pedal and hold.
  • Page 583 Readiness code Página 21 de 37 01-165 If "B1 P2 n.OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing.
  • Page 584 Readiness code Página 22 de 37 01-166 Indicated on display: (1...2 display System in basic setting 36 zones) If the diagnosis is initiated by the Motronic Engine Control Module (ECM) -J220- the display in display zone 2 jumps from "Test OFF" to "Test ON".
  • Page 585 Readiness code Página 23 de 37 01-167 If no DTC is stored: - Check Oxygen Sensor (O2S) and Oxygen Sensor (O2S) control after Three Way Catalytic Converter (TWC) Page 24-140 If "B1 P2 OK." appears in display zone 4: - Press -C- button. Work step 12: Three Way Catalytic Converter (TWC) diagnosis (checking conversion) Note:...
  • Page 586 Readiness code Página 24 de 37 01-168 Only continue with the test when: The Three Way Catalytic Converter (TWC) temperature is above 380 C (display zone - Depress brake pedal and accelerator down and hold until display in display zone 4 jumps from "Test OFF"...
  • Page 587 Readiness code Página 25 de 37 01-169 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 If no DTC is stored: - Press buttons -0- and -6- for the function "End...
  • Page 588 Readiness code Página 26 de 37 01-170 Indicated on display: (1...4 display System in basic setting 216 zones) - Observe figure displayed in display zone 4. Specification: xxxxx100 - Allow engine to run at idle until display zone 4 displays (after approx.
  • Page 589 Readiness code Página 27 de 37 01-171 Work step 14: Evaporative Emissions (EVAP) Canister system solenoid valve 1 diagnosis (Tank ventilation system) Indicated on display: Basic setting Input display group number XXX - Press buttons -0-, -7- and -0- for "Display group number 70"...
  • Page 590 Readiness code Página 28 de 37 01-172 Note: TBV stands for Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-. If "TBV n. OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking...
  • Page 591 Readiness code Página 29 de 37 01-173 - Check EVAP canister system for leaks: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 If "TBV OK." appears in display zone - Press -C- button. Work step 15: Secondary air system diagnosis Indicated on display: Basic setting...
  • Page 592 Readiness code Página 30 de 37 01-174 - Leave engine running at idle until display zone 4 displays: Specification: "Syst. OK." If "Syst.n.OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking...
  • Page 593 Readiness code Página 31 de 37 01-175 If "Syst. OK." appears in display zone 4: - Press button. Work step 16: Read readiness code - Read readiness code Page 01-146 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 594 Readiness code Página 32 de 37 01-176 Readiness code, generating (overview) Work steps 1 to 5: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 Diagnosis Check DTC 02/--- Ignition on memory Erase DTC 05/--- Ignition on memory Adapting...
  • Page 595 Readiness code Página 33 de 37 01-177 Work steps 6 to 9: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 Diagnosis Oxygen 08/30 Before After Three No display Idle speed Sensor Three (O2S) Catalytic control Catalytic Converter...
  • Page 596 Readiness code Página 34 de 37 01-178 Work Function/group Test Display Display Display Display step/ prerequisites zone 1 zone 2 zone 3 zone 4 Diagnosis 9 Oxygen 08/30 Before After Idle speed Sensor Three Three display display (O2S) control Catalytic Catalytic status Converter...
  • Page 597 Readiness code Página 35 de 37 01-179 Work steps 10 to 11: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Oxygen 04/43 Engine Three Way Oxygen Brakes Sensor speed Catalytic Sensor operated (O2S) after Converter (O2S) Three Way...
  • Page 598 Readiness code Página 36 de 37 01-180 Work steps 12 to 13: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Three 04/46 Engine Three Way Three Way Brakes speed Catalytic Catalytic operated Catalytic Converter Converter Converter...
  • Page 599 Readiness code Página 37 de 37 01-181 Work steps 14 to 16: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Evaporative 04/70 Evaporative Idle speed Emission Emissions quality display (EVAP) (EVAP) Canister Purge Canister RegulatorValve regulator...
  • Page 600 Readiness code Página 1 de 37 01-145 Readiness code Function The readiness code is an 8-digit number code which displays the status of the emission relevant diagnosis. When the diagnosis for a system (e.g. secondary air system) has been successfully completed, the corresponding position in the number code will change from 1 to 0.
  • Page 601 Readiness code Página 2 de 37 01-146 Read readiness code Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 Scan tool (or VAG 1552 vehicle system tester) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and...
  • Page 602 Readiness code Página 3 de 37 01-147 Must appear on display when all diagnosis functions have been successfully completed: Indicated on display: Readiness code 00000000 - Test complete - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button.
  • Page 603 Readiness code Página 4 de 37 01-148 Significance of figures in 8 digit number block, display zone 1 - Readiness code The readiness code is generated only when all display zones show 0 1 2 3 4 5 6 7 8 Diagnostic function 0 Three Way Catalytic Converter (TWC) Three Way Catalytic Converter (TWC) heating (currently no...
  • Page 604 Readiness code Página 5 de 37 01-149 Generating readiness code Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAG 1551 scan tool (or VAG 1552) with VAG 1551/3 Adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the vehicle diagnostic, testing and information system VAS 5051.
  • Page 605 Readiness code Página 6 de 37 01-150 The main fuses must be OK. The battery voltage must be at least 11.5 V. If the vehicle is equipped with air conditioning, this must be switched off. Selector lever must be in position "P"...
  • Page 606 Readiness code Página 7 de 37 01-151 Work sequence - Connect VAG 1551 scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with the "Address word" 01. (Connecting scan tool and selecting Engine Control Module (ECM) Page 01-12 Work step 1: Check DTC memory...
  • Page 607 Readiness code Página 8 de 37 01-152 Repair Diagnostic Trouble Codes (DTCs) printed out using DTC table: SAE P0 codes Page 01- SAE P1 codes Page 01- SAE P2 codes Page 01- SAE P3 codes Page 01- If no DTC is stored: - Press button.
  • Page 608 Readiness code Página 9 de 37 01-153 Note: If the ignition is switched off between "Check DTC memory" and "Erase DTC memory" the DTC memory will not be erased. - Press button. Work step 3: Adjust the Throttle Valve Control Module -J338- to the Motronic Engine Control Module (ECM) -J220- Indicated on display:...
  • Page 609 Readiness code Página 10 de 37 01-154 - Terminate engine basic setting at earliest after 30 seconds by pressing button. If the display does not indicate as described: - Check Throttle Valve Control Module -J338- Page 24-59 If the display indicates as described: - Start engine and run at idle.
  • Page 610 Readiness code Página 11 de 37 01-155 - Read Engine Coolant Temperature value in display zone 3. Specification: 85 to 110 C - Read Intake Air Temperature value in display zone 4. Specification: Ambient temperature less than 80 If the specifications are obtained: - Press button.
  • Page 611 Readiness code Página 12 de 37 01-156 Indicated on display: (1 to 4 System in basic setting 71 display zones) If "Reed op." appears in display zone - Open fuel tank filler cap briefly to release pressure in fuel tank. This will close reed terminal.
  • Page 612 Readiness code Página 13 de 37 01-157 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the...
  • Page 613 Readiness code Página 14 de 37 01-158 - Press buttons -0-, -3- and -0- for "Display group number 30" and confirm entry with -Q- button. Indicated on display: (1 to 2 display zones) Read measured value block 30 - Check Oxygen Sensor (O2S) control status before Three Way Catalytic Converter (TWC) (display zone 1): Specification: 111...
  • Page 614 Readiness code Página 15 de 37 01-159 Work step 7: Oxygen Sensor (O2S) aging diagnosis of Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC) Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -4- for function "Initiate basic setting"...
  • Page 615 Readiness code Página 16 de 37 01-160 Note: This process can take approx. 90 seconds. - Depress brake pedal and accelerator down until display zone 4 displays specification "B1-P1 OK.". - Release brake and accelerator pedals. If "B1 P1 n.OK." appears in display zone 4: - Press button.
  • Page 616 Readiness code Página 17 de 37 01-161 Work step 8: Fuel supply system diagnosis (part load) Indicated on display: Basic setting Input display group number XXX - Press buttons -2-, -1- and -6- for "Display group number 216" and confirm entry with -Q- button. Indicated on display: (1 to 4 System in basic setting 216 display zones)
  • Page 617 Readiness code Página 18 de 37 01-162 - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing. - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the...
  • Page 618 Readiness code Página 19 de 37 01-163 - Check Oxygen Sensor (O2S) control status after Three Way Catalytic Converter (TWC) (display zone 2): Specification: 111 Significance of figures in 3 digit number block Page 01-217 Note: The bits in display zone 2 will not be set to 1 until the Three Way Catalytic Converter (TWC) temperature rises above 380 C ( display...
  • Page 619 Readiness code Página 20 de 37 01-164 Indicated on display: Basic setting Input display group number XXX - Press buttons -0-, -4- and -3- for "Display group number 43" and confirm entry with -Q- button. Indicated on display: (1 to 4 System in basic setting 43 display zones) - Depress brake pedal and hold.
  • Page 620 Readiness code Página 21 de 37 01-165 If "B1 P2 n.OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking and erasing.
  • Page 621 Readiness code Página 22 de 37 01-166 Indicated on display: (1...2 display System in basic setting 36 zones) If the diagnosis is initiated by the Motronic Engine Control Module (ECM) -J220- the display in display zone 2 jumps from "Test OFF" to "Test ON".
  • Page 622 Readiness code Página 23 de 37 01-167 If no DTC is stored: - Check Oxygen Sensor (O2S) and Oxygen Sensor (O2S) control after Three Way Catalytic Converter (TWC) Page 24-140 If "B1 P2 OK." appears in display zone 4: - Press -C- button. Work step 12: Three Way Catalytic Converter (TWC) diagnosis (checking conversion) Note:...
  • Page 623 Readiness code Página 24 de 37 01-168 Only continue with the test when: The Three Way Catalytic Converter (TWC) temperature is above 380 C (display zone - Depress brake pedal and accelerator down and hold until display in display zone 4 jumps from "Test OFF"...
  • Page 624 Readiness code Página 25 de 37 01-169 - Read readiness code Page 01-146 . If the DTC memory has been erased or the Motronic Engine Control Module (ECM) -J220- was disconnected from battery (B+) positive, the readiness code must be generated again Page 01-149 If no DTC is stored: - Press buttons -0- and -6- for the function "End...
  • Page 625 Readiness code Página 26 de 37 01-170 Indicated on display: (1...4 display System in basic setting 216 zones) - Observe figure displayed in display zone 4. Specification: xxxxx100 - Allow engine to run at idle until display zone 4 displays (after approx.
  • Page 626 Readiness code Página 27 de 37 01-171 Work step 14: Evaporative Emissions (EVAP) Canister system solenoid valve 1 diagnosis (Tank ventilation system) Indicated on display: Basic setting Input display group number XXX - Press buttons -0-, -7- and -0- for "Display group number 70"...
  • Page 627 Readiness code Página 28 de 37 01-172 Note: TBV stands for Evaporative Emission (EVAP) Canister Purge RegulatorValve -N80-. If "TBV n. OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking...
  • Page 628 Readiness code Página 29 de 37 01-173 - Check EVAP canister system for leaks: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 If "TBV OK." appears in display zone - Press -C- button. Work step 15: Secondary air system diagnosis Indicated on display: Basic setting...
  • Page 629 Readiness code Página 30 de 37 01-174 - Leave engine running at idle until display zone 4 displays: Specification: "Syst. OK." If "Syst.n.OK." appears in display zone 4: - Press button. - Check DTC memory, repair Diagnostic Trouble Codes (DTCs) if necessary and then erase DTC memory Page 01-23 , DTC memory, checking...
  • Page 630 Readiness code Página 31 de 37 01-175 If "Syst. OK." appears in display zone 4: - Press button. Work step 16: Read readiness code - Read readiness code Page 01-146 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 631 Readiness code Página 32 de 37 01-176 Readiness code, generating (overview) Work steps 1 to 5: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 Diagnosis Check DTC 02/--- Ignition on memory Erase DTC 05/--- Ignition on memory Adapting...
  • Page 632 Readiness code Página 33 de 37 01-177 Work steps 6 to 9: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 Diagnosis Oxygen 08/30 Before After Three No display Idle speed Sensor Three (O2S) Catalytic control Catalytic Converter...
  • Page 633 Readiness code Página 34 de 37 01-178 Work Function/group Test Display Display Display Display step/ prerequisites zone 1 zone 2 zone 3 zone 4 Diagnosis 9 Oxygen 08/30 Before After Idle speed Sensor Three Three display display (O2S) control Catalytic Catalytic status Converter...
  • Page 634 Readiness code Página 35 de 37 01-179 Work steps 10 to 11: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Oxygen 04/43 Engine Three Way Oxygen Brakes Sensor speed Catalytic Sensor operated (O2S) after Converter (O2S) Three Way...
  • Page 635 Readiness code Página 36 de 37 01-180 Work steps 12 to 13: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Three 04/46 Engine Three Way Three Way Brakes speed Catalytic Catalytic operated Catalytic Converter Converter Converter...

  • Page 636: Readiness Code

    Readiness code Página 37 de 37 01-181 Work steps 14 to 16: Work step/ Function/group Test Display Display Display prerequisites zone 1 zone 2 zone 3 diagnosis Evaporative 04/70 Evaporative Idle speed Emission Emissions quality display (EVAP) (EVAP) Canister Purge Canister RegulatorValve regulator...
  • Page 637 Measured value (data) blocks Página 1 de 86 01-182 Measured value (data) blocks Safety precautions Observe following if test and measuring instruments are required during a road test: Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this location.
  • Page 638 Measured value (data) blocks Página 2 de 86 01-183 Read measured value (data) block The measured values in the functions read measured value block and basic setting are described during the individual component test. This table serves only as an overview.
  • Page 639 Measured value (data) blocks Página 3 de 86 01-184 The main fuses must be OK. The battery voltage must be at least 11.5 V. Ground (GND) connection between engine and body must be OK. All electrical devices, e.g. lights and rear window defroster must be switched off.
  • Page 640 Measured value (data) blocks Página 4 de 86 01-185 Work sequence - Connect VAG 1551 scan tool ((VAG 1552) and select Engine Control Module (ECM) with the "Address word" 01. When doing this the engine must be running at idle: (Connecting scan tool and selecting Engine Control Module (ECM) Page 01-12 Indicated on display:...
  • Page 641 Measured value (data) blocks Página 5 de 86 01-186 Indicated on display: (1...4 display Read measured value block 1 zones) Note: To change to another display group proceed as follows: Display VAG 1552 group 1551 Higher Press -Press button -3- button Lower Press...

  • Page 642: Converter (Twc)

    Measured value (data) blocks Página 6 de 86 01-187 Measured value blocks, display groups 0...9 - Basic functions, evaluating Display group 1 - Basic functions Engine running at idle Read measured Indicated on value block 1 display xxxx xxx.x xx.x xxxxxxxx Specification Evaluation...

  • Page 643: Greater Than

    Measured value (data) blocks Página 7 de 86 01-188 Evaluating display group 1, display zone 1 - Engine speed (idle speed) VAG 1551 Possible cause Corrective action display Less than Throttle Valve Control Module - - Check Throttle Valve specified J338- sticking/faulty Control Module -J338- Page 24-59...
  • Page 644 Measured value (data) blocks Página 8 de 86 01-189 Significance of figures in 8 digit number block, display zone 4 - Adjustment conditions Significance if display = 1 1 2 3 4 5 6 7 8 Significance 1 Coolant temperature above 80 C Speed below 2000 rpm Throttle valve closed Oxygen Sensor (O2S) control active...
  • Page 645 Measured value (data) blocks Página 9 de 86 01-190 Display group 2 - Basic functions - Mass Air Flow (MAF) Sensor Engine running at idle Read measured value Indicated on block 2 display xxxx rpm xxx.x % xx.x Specification Evaluation Display zones Air mass drawn in 3.0...5.0 g/s...
  • Page 646 Measured value (data) blocks Página 10 de 86 01-191 Evaluating display group 2, display zone 4 - Mass Air Flow (MAF) Appears on Possible cause Corrective action display Less than Large amount of unmetered air - Repair unmetered air specified between intake manifold and Mass Air Flow (MAF) Sensor -G70- Greater than...
  • Page 647 Measured value (data) blocks Página 11 de 86 01-192 Display group 3 - Basic function - Mass Air Flow (MAF) Engine running at idle Read measured value Indicated on block 3 display xxxx xx.x xx.x xx.x Specification Evaluation Display zones Ignition timing 4.0...15.0 angle...
  • Page 648 Measured value (data) blocks Página 12 de 86 01-193 Display group 4 - Basic functions Engine running at idle Read measured value Indicated on block 4 display xxxx xx.xxx xxx.x xxx.x Specification Evaluation Display zones Intake air -37.0...126.0 Page 01- temperature Coolant temperature Page 01-...
  • Page 649 Measured value (data) blocks Página 13 de 86 01-194 Evaluating display group 4, display zone 2 - control module voltage supply Appears on Possible cause Corrective action display Less than Alternator faulty, battery charge - Check alternator and specified state low battery voltage, charge battery: Repair Manual, Electrical...
  • Page 650 Measured value (data) blocks Página 14 de 86 01-195 Evaluating display group 4, display zone 3 - Engine Coolant Temperature (ECT) Appears on Possible cause Corrective action display Less than - If necessary perform road test Engine too cold specified Engine Coolant - Check Engine Coolant Temperature Temperature (ECT)
  • Page 651 Measured value (data) blocks Página 15 de 86 01-196 Evaluating display group 4, display zone 4 - Intake air temperature (IAT) Appears on Possible cause Corrective action display Less/greater than Intake Air Temperature - Check Intake Air Temperature specified (IAT) sensor -G42- faulty (IAT) sensor -G42- Page 24-81 Constant -37.0...
  • Page 652 Measured value (data) blocks Página 16 de 86 01-197 Display group 5 - Basic function Engine running at idle Read measured Indicated on display value block 5 xxxx xxx.x Text km/h Specification Evaluation Display zones Operating mode: idling, part throttle, Idle speed enrichment, overrun, wide open throttle...
  • Page 653 Measured value (data) blocks Página 17 de 86 01-198 Display group 6 - Basic function Engine running at idle Read measured value Indicated on block 6 display xxxx xxx.x xxx.x xx.x Specification Evaluation Display zones Elevation -50.0...20.0 % correction factor Intake air temperature -37.0...126.0 Page 01-...
  • Page 654 Measured value (data) blocks Página 18 de 86 01-199 Display group 8 - Basic functions - Brake System Vacuum Pump (automatic transmission only) Ignition on, engine not running Read measured value Indicated on block 8 display Text xx.xxx Text mbar Specification Evaluation Display zones...
  • Page 655 Measured value (data) blocks Página 19 de 86 01-200 Measured value blocks, display groups 10...29 - Ignition, evaluating Display group 10 - Ignition Engine running at idle Read measured value Indicated on block 10 display xxxx xxx.x xxx.x xx.x BTDC Specification Evaluation Display...
  • Page 656 Measured value (data) blocks Página 20 de 86 01-201 Evaluating display group 10, display zone 2 - Engine load Appears on Possible cause Corrective action display Less than Lower values can only occur specified when driving in overrun Greater than Rough idling (not running on - Check spark connectors Page...
  • Page 657 Measured value (data) blocks Página 21 de 86 01-202 Evaluating display group 10, display zone 3 - Throttle valve angle, Angle sensor - 1- for throttle drive Appears on Possible cause Corrective action display Greater Motronic Engine Control - Erase learned values and adapt than Module (ECM) -J220- not Motronic Engine Control Module...
  • Page 658 Measured value (data) blocks Página 22 de 86 01-203 Display group 14 - Ignition - Misfire detection While driving Read measured value Indicated on block 14 display xxxx rpm xxx.x % Text Specification Evaluation Display zones Misfire detection (inactive, Activated activated) Misfire total Page 01-...
  • Page 659 Measured value (data) blocks Página 23 de 86 01-204 Evaluating display group 14, display zone 3 - Total number of misfires Appears on Possible cause Corrective action display Greater than - Check spark connectors Page 28- Spark connector faulty specified Ignition coil faulty - Check ignition coils with final output stage...
  • Page 660 Measured value (data) blocks Página 24 de 86 01-205 Display group 15 - Ignition - Misfire detection cyl. 1 to cyl. 3 While driving Read measured value Indicated on block 15 display Text Specification Evaluation Display zones Misfire detection (inactive, Activated activated) Ignition misfire cyl.
  • Page 661 Measured value (data) blocks Página 25 de 86 01-206 Display group 16 - Ignition - Misfire detection cyl. 4 to cyl. 6 While driving Read measured value Indicated on block 16 display Text Specification Evaluation Display zones Misfire detection (inactive, Activated activated) Ignition misfire cyl.
  • Page 662 Measured value (data) blocks Página 26 de 86 01-207 Evaluating display group 15, display zones 1 to 3 or display group 16, display zones 1 to 3 - Ignition misfires cyl. 1 to cyl. 6 Appears on Possible cause Corrective action display Greater than - Check spark connectors...
  • Page 663 Measured value (data) blocks Página 27 de 86 01-208 Display group 20 - Ignition Knock control cyl. 1 to cyl. 4 While driving Read measured value Indicated on block 20 display xx.x xx.x xx.x xx.x Specification Evaluation Display zones Ignition timing retardation cyl.
  • Page 664 Measured value (data) blocks Página 28 de 86 01-209 Display group 21 - Ignition Knock control cyl. 5 and cyl. 6 While driving Read measured value Indicated on block 21 display xx.x CA xx.x CA Specification Evaluation Display zones No display No display Ignition timing retardation cyl.
  • Page 665 Measured value (data) blocks Página 29 de 86 01-210 Evaluating display group 20, display zones 1 to 4 and display group 21, display zones 1 and 2 - Ignition timing retardation cyl. 1 to cyl. 6 Appears on Possible cause Corrective action display All cylinders...
  • Page 666 Measured value (data) blocks Página 30 de 86 01-211 Display group 22 - Ignition Knock control cyl. 1 and cyl. 2 While driving Read measured value Indicated on block 22 display xxxx xxx.x xx.x xx.x Specification Evaluation Display zones Ignition timing retardation cyl.
  • Page 667 Measured value (data) blocks Página 31 de 86 01-212 Display group 23 - Ignition Knock control cyl. 3 and cyl. 4 While driving Read measured value Indicated on block 23 display xxxx xxx.x xx.x xx.x Specification Evaluation Display zones Ignition timing retardation cyl.
  • Page 668 Measured value (data) blocks Página 32 de 86 01-213 Display group 24 - Ignition - Knock control cyl. 5 and cyl. 6 While driving Read measured value Indicated on block 24 display xxxx xxx.x xx.x xx.x Specification Evaluation Display zones Ignition timing retardation cyl.
  • Page 669 Measured value (data) blocks Página 33 de 86 01-214 Evaluating display groups 22 to 24, display zones 3 and 4 - Ignition timing retardation cyl. 1 to 6 Appears on Possible cause Corrective action display All cylinders Knock sensor - Check knock sensors Page 28-30 between faulty...
  • Page 670 Measured value (data) blocks Página 34 de 86 01-215 Display group 28 - Ignition - Knock control Control module in function "04-Basic setting" Vehicle stationary, engine running at increased idle speed (only with brake and accelerator pedals depressed) System in basic Indicated on display setting 28 xxxx...
  • Page 671 Measured value (data) blocks Página 35 de 86 01-216 Measured value blocks, display groups 30...33, 99 - Oxygen Sensor (O2S) control, evaluating Display group 30 - Oxygen Sensor (O2S) control Engine running at idle Read measured value Indicated on display block 30 Specification Evaluation...
  • Page 672 Measured value (data) blocks Página 36 de 86 01-217 Significance of characters in 3 digit number block, display zones 1 and 2 - Status of Oxygen Sensor (O2S) control before and after Three Way Catalytic Converter (TWC) Significance if display = 1 1 2 3 Significance 1 Oxygen Sensor (O2S) control active...
  • Page 673 Measured value (data) blocks Página 37 de 86 01-218 Display group 31 - Oxygen Sensor (O2S) control constantly operating Oxygen Sensors Engine running at idle Read measured value Indicated on block 31 display x.xx x.xx Specification Evaluation Display zones No display No display Oxygen Sensor (O2S) control, 1.00...
  • Page 674 Measured value (data) blocks Página 38 de 86 01-219 Display group 32 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) learned values before Three Way Catalytic Converter (TWC) Engine running at idle Read measured Indicated on value block 32 display xx.x xx.x...
  • Page 675 Measured value (data) blocks Página 39 de 86 01-220 Note on display zones 1 and 2: Low values indicate that the engine is running too rich and therefore the Oxygen Sensor (O2S) control is leaning the mixture. High values indicate that the engine is running too lean and therefore the Oxygen Sensor (O2S) control enriches the mixture.
  • Page 676 Measured value (data) blocks Página 40 de 86 01-221 Evaluating display group 32, display zones 1 and 2 - Oxygen Sensor (O2S) learned values before Three Way Catalytic Converter (TWC) Appears on Possible cause Corrective action display Low Oxygen Low learned values at idling - Disappears after Sensor (O2S) but with normal learned...
  • Page 677 Measured value (data) blocks Página 41 de 86 01-222 Appears on Possible cause Corrective action display High Oxygen High learned values at idle, not so - Check intake air system for Sensor high learned values at part throttle: leaks Page 24-121 (O2S) Possible unmetered air in area of intake manifold...
  • Page 678 Measured value (data) blocks Página 42 de 86 01-223 Display group 33 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) learned values before Three Way Catalytic Converter (TWC) Engine running at idle Read measured Indicated on value block 33 display xx.x x.xxx...
  • Page 679 Measured value (data) blocks Página 43 de 86 01-224 Evaluating display group 33, display zone 1 - Oxygen Sensor (O2S) control before Three Way Catalytic Converter (TWC) Appears on Possible cause Corrective action display Outside Minus range: Mixture too rich, - Wait 30 seconds until tolerance Oxygen Sensor (O2S) control...
  • Page 680 Measured value (data) blocks Página 44 de 86 01-225 Evaluating display group 33, display zone 2 - Oxygen Sensor (O2S) control before Three Way Catalytic Converter (TWC) Appears Possible cause Corrective action on display Constant Wiring open circuit via: Oxygen - Check Oxygen Sensor (O2S) 1.5 V Sensor (O2S), sensor wiring,...
  • Page 681 Measured value (data) blocks Página 45 de 86 01-226 Display group 34 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) aging diagnosis of Oxygen Sensor (O2S) before Three Way Catalytic Converter (TWC) Control module in function "04-Basic setting" Vehicle stationary, engine running at increased idle speed (only with depressed brake pedal and accelerator) System in basic Indicated on display...
  • Page 682 Measured value (data) blocks Página 46 de 86 01-227 Evaluation of display group 34, display zone 4 - Oxygen Sensor (O2S) diagnosis - Oxygen Sensor (O2S) aging before Three Way Catalytic Converter (TWC) Appears on display Possible cause Corrective action Oxygen Sensor (O2S) DTC stored in DTC - Check DTC memory...
  • Page 683 Measured value (data) blocks Página 47 de 86 01-228 Display group 36 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) diagnosis after Three Way Catalytic Converter (TWC) (operational readiness) Control module in function "04-Basic setting" Engine running at idle System in basic Indicated on setting 36...
  • Page 684 Measured value (data) blocks Página 48 de 86 01-229 Evaluating display group 36, display zone 1 - Oxygen Sensor (O2S) voltage,Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) Appears on Possible cause Corrective action display Constant 1.100 Short to positive via: Oxygen - Check basic voltage of Sensor (O2S), sensor wiring, Oxygen Sensor (O2S) after...
  • Page 685 Measured value (data) blocks Página 49 de 86 01-230 Evaluating display group 36, display zone 2 - Diagnosis of Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) Appears on display Possible cause Corrective action Oxygen Sensor (O2S) DTC stored in DTC - Check DTC memory Page after Three Way...
  • Page 686 Measured value (data) blocks Página 50 de 86 01-231 Display group 41 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) heating Engine running at idle Read measured Indicated on display value block 41 --- Text xx.xx Text Specification Evaluation Display zones Oxygen Sensor (O2S) Htg.nC.ON...
  • Page 687 Measured value (data) blocks Página 51 de 86 01-232 Display group 43 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) aging diagnosis of Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) Control module in function "04-Basic setting" Vehicle stationary, engine running at increased idle speed (only with depressed brake pedal and accelerator) System in basic Indicated on display...
  • Page 688 Measured value (data) blocks Página 52 de 86 01-233 Evaluation of display group 43, display zone 4 - Oxygen Sensor (O2S) diagnosis - Oxygen Sensor (O2S) aging after Three Way Catalytic Converter (TWC) Appears on display Possible cause Corrective action Oxygen Sensor (O2S) DTC stored in DTC - Check DTC memory...
  • Page 689 Measured value (data) blocks Página 53 de 86 01-234 Display group 46 - Oxygen Sensor (O2S) control - Three Way Catalytic Converter (TWC) diagnosis (conversion test) Control module in function "04-Basic setting" Vehicle stationary, engine running at increased idle speed (only with depressed brake pedal and accelerator) System in basic Indicated on display...
  • Page 690 Measured value (data) blocks Página 54 de 86 01-235 Evaluating display group 46, display zone 4 - Three Way Catalytic Converter (TWC) diagnosis (conversion test) Appears on display Possible cause Corrective action Three Way Catalytic DTC stored in DTC - Check DTC memory Page 01- Converter (TWC) not memory...
  • Page 691 Measured value (data) blocks Página 55 de 86 01-236 Display group 99 - Oxygen Sensor (O2S) control - Oxygen Sensor (O2S) control operating condition Engine running at idle Control module in function "04-Basic setting", Oxygen Sensor (O2S) control off Control module in function "08-Read measured value block", Oxygen Sensor (O2S) control on System in basic Indicated on display...
  • Page 692 Measured value (data) blocks Página 56 de 86 01-237 Measured value blocks, display groups 50...69 - Speed control, Evaluating Display group 50 - Speed control - Operating condition Engine running at idle Read measured value Indicated on display block 50 xxxx xxxx Text Text...
  • Page 693 Measured value (data) blocks Página 57 de 86 01-238 Display group 54 - Speed control While driving Read measured value Indicated on block 54 display xxxx Text xxx.x xxx.x Specification Evaluation Display zones Throttle valve angle Angle sensor -1- for 0.0...100.0 % throttle drive -G187- Throttle valve angle...
  • Page 694 Measured value (data) blocks Página 58 de 86 01-239 Display group 55 - Speed control - Idling stabilization Engine running at idle Read measured value Indicated on block 55 display xxxx xx.x xx.x xxxxx Specification Evaluation Display zones Operating xxxxx Page 01- condition Idling stabilization learning...
  • Page 695 Measured value (data) blocks Página 59 de 86 01-240 Significance of figures in 5 digit number block, display zone 4 - Operating conditions Significance if display = 1 1 2 3 4 5 Significance 1 Air conditioner compressor switched on Drive gear selected Air conditioning system switched on Not relevant...
  • Page 696 Measured value (data) blocks Página 60 de 86 01-241 Display group 56 - Speed control - Idling stabilization Engine running at idle Read measured value Indicated on block 56 display xxxx xxxx xx.x xxxxx Specification Evaluation Display zones Operating xxxxx Page 01- condition Idling control...
  • Page 697 Measured value (data) blocks Página 61 de 86 01-242 Display group 57 - Speed control - Idling stabilization Engine running at idle Read measured value Indicated on block 57 display xxxx xxxx Text Specification Evaluation Display zones No display Air conditioning compressor Compr.
  • Page 698 Measured value (data) blocks Página 62 de 86 01-243 Display group 60 - Speed control - Electronic power control (EPC) system adaption Control module in function "04-Basic setting" Ignition on, engine not running System in basic Indicated on display setting 60 xxx % xxx % Text...
  • Page 699 Measured value (data) blocks Página 63 de 86 01-244 Note on display group 60: Adapting the Throttle Valve Control Module -J338- is performed with ignition switched on. Motronic Engine Control Module (ECM) -J220- is adapted to throttle valve control module when selecting display group 60 under function "04-Basic setting". This adaption must always be carried out when another Throttle Valve Control Module - J338- (or another complete engine) or another Motronic Engine Control Module (ECM) -J220- is installed.
  • Page 700 Measured value (data) blocks Página 64 de 86 01-245 Display group 61 - Speed control - Electronic Power Control system While driving Read measured value Indicated on block 61 display xxxx xx.xxx xxx.x xxxxx Specification Evaluation Display zones Operating xxxxx Page 01- condition Throttle valve angle...
  • Page 701 Measured value (data) blocks Página 65 de 86 01-246 Display group 62 - Speed control - Electronic Power Control system Ignition on, engine not running Read measured Indicated on display value block 62 Specification Evaluation Display zones Sender -2- for accelerator pedal position -G185- 4...49 % Throttle Position (TP) Sensor -...
  • Page 702 Measured value (data) blocks Página 66 de 86 01-247 Display group 66 - Speed control - Additional signals Engine running at idle Read measured value Indicated on block 66 display xxxxxxxx xxxx km/h km/h Specification Evaluation Display zones Switch position of 00000000 Page 01- CCS controls switch...
  • Page 703 Measured value (data) blocks Página 67 de 86 01-248 Significance of figures in 8 digit number block, display zone 2 - Switch positions Significance if display = 1 1 2 3 4 5 6 7 8 Significance 1 Brake depressed (Brake Light Switch -F-) Brake depressed (Brake Vacuum Vent Valve Switch -F47-) Clutch depressed (Clutch Vacuum Vent Valve Switch -F36- Cruise control system operational...
  • Page 704 Measured value (data) blocks Página 68 de 86 01-249 Significance of figures in 8 digit number block, display zone 4 - CCS controls switch Significance if display = 1 1 2 3 4 5 6 7 8 Significance 0 CCS sliding switch at off (only with detent) CCS sliding switch at off (not in detent or in detent) SET button depressed CCS sliding switch at RES...
  • Page 705 Measured value (data) blocks Página 69 de 86 01-250 Measured value blocks, display groups 70...77 - Reducing emissions, evaluating Display group 70 - Reducing emissions - Evaporative Emissions (EVAP) Canister system regulatorvalve diagnosis (Fuel Tank ventilation system) Control module in function "04-Basic setting" Engine running at idle System in basic Indicated on display...
  • Page 706 Measured value (data) blocks Página 70 de 86 01-251 Note on display zone 1: The total range is given. Note on display zone 2: Oxygen Sensor (O2S) control deviation in negative range: Evaporative Emissions (EVAP) Canister full Oxygen Sensor (O2S) control deviation in positive range: Evaporative Emissions (EVAP) Canister empty http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 707 Measured value (data) blocks Página 71 de 86 01-252 Evaluating display group 70, display zone 4 - Evaporative Emissions (EVAP) Canister system regulator valve diagnosis (Fuel Tank ventilation system) Appears on display Possible cause Corrective action Check not performed - Check DTC memory DTC stored in DTC memory or has not finished: Page 01-23...
  • Page 708 Measured value (data) blocks Página 72 de 86 01-253 Appears on Possible cause Corrective action display Functions Fuel - Check DTC memory Page DTC stored in DTC memory tank breather not 01-23 , DTC memory, checking OK.: TEV n. and erasing Breather line between EVAP - Check breather line for through canister purge regulator...
  • Page 709 Measured value (data) blocks Página 73 de 86 01-254 Display group 71 - Reducing emissions - Evaporative Emissions (EVAP) Canister system diagnosis (leak diagnosis) Control module in function "04-Basic setting" Engine running at idle System in basic Indicated on display setting 71 Text Text...
  • Page 710 Measured value (data) blocks Página 74 de 86 01-255 Evaluating display group 71, display zone 4 - Evaporative Emissions (EVAP) Canister diagnosis (leak diagnosis) Appears on display Possible cause Corrective action Check not performed - Check DTC memory DTC stored in DTC memory or has not finished: Page 01-23 , DTC memory,...
  • Page 711 Measured value (data) blocks Página 75 de 86 01-256 Appears on Possible cause Corrective action display Functions Leak DTC stored in DTC - Check DTC memory Page 01- diagnosis not OK.: memory , DTC memory, checking and Syst. n.OK. erasing Evaporative Emissions - Check Evaporative Emissions (EVAP) Canister...
  • Page 712 Measured value (data) blocks Página 76 de 86 01-257 Display group 77 - Reducing emissions - Secondary air system diagnosis Control module in function "04-Basic setting" Engine running at idle System in basic Indicated on display setting 77 xxxx xx.x xxx.x Text Specification...
  • Page 713 Measured value (data) blocks Página 77 de 86 01-258 Evaluating display group 77, display zone 4 - Secondary air system diagnosis Appears on display Possible cause Corrective action Check not performed - Check DTC memory DTC stored in DTC memory or has not finished: Page 01-23 , DTC memory,...
  • Page 714 Measured value (data) blocks Página 78 de 86 01-259 Appears on Possible cause Corrective action display Functions Leak DTC stored in DTC - Check DTC memory Page 01- diagnosis not OK.: memory , DTC memory, checking and Syst. n.OK. erasing Secondary Air Injection - Check Secondary Air Injection (AIR) Solenoid Valve -...
  • Page 715 Measured value (data) blocks Página 79 de 86 01-260 Measured value blocks, display groups 86...89, 100 - Readiness code, evaluating Display group 86 - Readiness code Engine running at idle Read measured value block 86 Indicated on display xxxxxxxx xxxxxxxx xxxxxxxx Specification Evaluation Display...
  • Page 716 Measured value (data) blocks Página 80 de 86 01-261 Significance of figures in 8 digit number block, display zone 1 - Readiness code The readiness code is generated only when all display zones show 0 1 2 3 4 5 6 7 8 Diagnostic function 0 Three Way Catalytic Converter (TWC) Three Way Catalytic Converter (TWC) heating (currently no...
  • Page 717 Measured value (data) blocks Página 81 de 86 01-262 Display group 89 - Distance recorder - Malfunction Indicator Light (MIL) on Engine running at idle Read measured value Indicated on block 89 display xxxx Text Specification Evaluation Display zones No display No display Level of fuel in fuel tank (OK.
  • Page 718 Measured value (data) blocks Página 82 de 86 01-263 Display group 100 - Readiness code Engine running at idle Read measured value Indicated block 100 on display xxxxxxxx xxx.x xxx.xx xxxxxxxx Specification Evaluation Display zones Diagnosis status Period since engine started Engine Coolant Temperature 80.0...110.0...
  • Page 719 Measured value (data) blocks Página 83 de 86 01-264 Measured value blocks, display groups 90...96 - Performance improvement, evaluating Display group 90 - Performance improvement - Exhaust camshaft timing adjustment While driving Read measured value Indicated on block 90 display xxxx Text xx.x...
  • Page 720 Measured value (data) blocks Página 84 de 86 01-265 Display group 91 - Performance improvement - Inlet camshaft continuously variable timing adjustment While driving Read measured value Indicated on block 91 display xxxx xxx.x xx.x xx.x Specification Evaluation Display zones Camshaft timing 0.0...52.0 adjustment angle...
  • Page 721 Measured value (data) blocks Página 85 de 86 01-266 Display group 95 - Performance improvement - Variable intake manifold change over While driving Read measured value Indicated on block 95 display xxxx xxx.x xxx.x Text Specification Evaluation Display zones Variable intake IMC-V OFF / manifold change-over status...
  • Page 722 Measured value (data) blocks Página 86 de 86 01-267 Measured value blocks, display groups 120...129 - Communication, evaluating Display group 125 - Communication - Can-bus messages Engine running at idle Read measured value block Indicated on display Text Text Text Specification Evaluation Display zones No display...
  • Page 723 Fuel injection system, servicing Página 1 de 58 24-1 Fuel injection system, servicing Component locations overview 1 - Heated Oxygen Sensor (HO2S) -G39-, 50 Nm Component location: In front exhaust pipe 2 - Connector Gold plated terminals Black, 6-pin Heated Oxygen Sensor (HO2S)
  • Page 724 Fuel injection system, servicing Página 2 de 58 Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130-, 50 Component location: Behind Three Way Catalytic Converter (TWC) - G130- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 725 Fuel injection system, servicing Página 3 de 58 24-2 4 - Connector Black, 4-pin Terminals 3 and 4 gold plated Oxygen Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130- Oxygen Sensor (O2S) Heater 1 -Z29- Component location: Right on underside of vehicle 5 - Knock...
  • Page 726 Fuel injection system, servicing Página 4 de 58 Module (ECM) - J220- Disconnect or connect only with ignition switched Release to disconnect 7 - Motronic Engine Control Module (ECM) - J220- Component location: In plenum chamber http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 727 Fuel injection system, servicing Página 5 de 58 24-3 8 - Clutch Vacuum Vent Valve Switch - F36-, Brake Light Switch - F- and Brake Vacuum Vent Valve Switch - F47- Component location: In left footwell Checking signal from Clutch Vacuum Vent Valve...
  • Page 728 Fuel injection system, servicing Página 6 de 58 (CMP) Sensor - G40- intake camshaft Page 28-7 item 16 Mark connector component before pulling connector http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 729 Fuel injection system, servicing Página 7 de 58 24-4 Valve -1- camshaft adjustment -N205- intake camshaft Mark connector component before pulling connector off. Checking activation Page 01-100 Output Diagnosis Test Mode (DTM) Check camshaft timing adjustment: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s):...
  • Page 730 Fuel injection system, servicing Página 8 de 58 Mark connector component before pulling connector off. Checking activation Page 01-100 Output Diagnosis Test Mode (DTM) Check camshaft timing adjustment: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 15, Valve train, servicing http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=...
  • Page 731 Fuel injection system, servicing Página 9 de 58 24-5 12 - Camshaft Position (CMP) Sensor 2 - G163- exhaust camshaft Page 28-6 item 13 Mark connector component before pulling connector off. 13 - Protective housing Relay assignment protective housing Fig. 1 Mass Air Flow (MAF) sensor -...
  • Page 732 Fuel injection system, servicing Página 10 de 58 Manifold Change- Over Valve - N156- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...

  • Page 733: Rpm

    Fuel injection system, servicing Página 11 de 58 24-6 Engine Coolant Temperature (ECT) sensor - G62- Motronic Engine Control Module (ECM) - J220- With Engine Coolant Temperature Gauge sensor -G2- Release pressure in cooling system if necessary before removing components 19 - Engine Speed (RPM)
  • Page 734 Fuel injection system, servicing Página 12 de 58 (AIR) Pump Motor - V101- Checking activation Page 01-100 Output Diagnosis Test Mode (DTM) Secondary system: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 26 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 735 Fuel injection system, servicing Página 13 de 58 24-7 22 - Intake Manifold Change- Over Valve - N156- Secondary Injection (AIR) Solenoid Valve - N112- Checking activation Page 01-100 Output Diagnosis Test Mode (DTM) Secondary system: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s):...
  • Page 736 Fuel injection system, servicing Página 14 de 58 activation Page 01-100 Output Diagnosis Test Mode (DTM) Evaporative Emission (EVAP) Canister system Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 737 Fuel injection system, servicing Página 15 de 58 24-8 26 - Throttle Valve Control Module -J338- Heated coolant 27 - Combi- valve Secondary system: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code (s): BDF; Repair Group 28 - Ignition coils with power...
  • Page 738 Fuel injection system, servicing Página 16 de 58 24-9 Fig. 1 Relay assignment in protective housing (on left in engine compartment) 1 - Secondary Air Injection (AIR) Pump Relay -J299- 2 - Motronic Engine Control Module (ECM) Power Supply Relay -J271- Note: If tools are necessary to pull relays or control modules out of...
  • Page 739 Fuel injection system, servicing Página 17 de 58 24-10 Fuel injection system, general notes Servicing ignition parts: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group Note: The Motronic Engine Control Module (ECM) - J220- is equipped with On Board Diagnostic (OBD).
  • Page 740 Fuel injection system, servicing Página 18 de 58 24-11 Check DTC memory before carrying out repairs and when troubleshooting Page 01-23 Checking and erasing DTC memory During some checks it is possible that the control module will detect and store a Diagnostic Trouble Code (DTC).
  • Page 741 Fuel injection system, servicing Página 19 de 58 24-12 Fuel injection system components, removing installing 1 - Secondary Injection (AIR) Solenoid Valve - N112-*/** Component location Page 24-1 Component locations overview Valve will be activated Motronic Engine Control Module (ECM) - J220- (pulsed) Secondary...
  • Page 742 Fuel injection system, servicing Página 20 de 58 Change- Over Valve - N156-*/** Component location Page 24-1 Component locations overview Valve will be activated Motronic Engine Control Module (ECM) - J220- (pulsed) Checking Intake Manifold Change- Over Valve - N156- Page 24- 3 - Vacuum actuator...
  • Page 743 Fuel injection system, servicing Página 21 de 58 24-13 4 - Vacuum reservoir Intake Manifold Change- Over Valve - N156- Removing installing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 26 5 - Intake manifold Disassembling assembling Page 24-22...
  • Page 744 Fuel injection system, servicing Página 22 de 58 installing Page 24-22 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 745 Fuel injection system, servicing Página 23 de 58 24-14 7 - Vacuum line Press together at front release 8 - Motronic Engine Control Module (ECM) - J220-* (Motronic control module - J220- Component location: In plenum chamber Checking voltage supply Page 24- Procedure after...
  • Page 746 Fuel injection system, servicing Página 24 de 58 values adapt Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338- Page 24- Supporting frame http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 747 Fuel injection system, servicing Página 25 de 58 24-15 10 - Connector Motronic Engine Control Module (ECM) - J220- Disconnect or connect only with ignition switched Release to disconnect 11 - Retaining clip Check seated securely 12 - Thermostat housing Component location Page 24-1...
  • Page 748 Fuel injection system, servicing Página 26 de 58 24-16 Engine Coolant Temperature (ECT) sensor - G62-* Motronic Engine Control Module (ECM) - J220- With Engine Coolant Temperature (ECT) sensor -G2- Gold plated terminals Release pressure in cooling system if necessary before removing components...
  • Page 749 Fuel injection system, servicing Página 27 de 58 Checking Page 24-93 17 - Connector Black, 4- Terminals 3 and 4 are gold plated Oxygen Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130- Oxygen Sensor (O2S) Heater 1 -Z29- Component location: Right on underside...
  • Page 750 Fuel injection system, servicing Página 28 de 58 24-17 Oxygen Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130-*, 50 Nm Component location: In rear of Three Way Catalytic Converter Remove install with ring wrench 3337 Grease only threads with G 052 112 A3 hot bolt paste (anti-seize...
  • Page 751 Fuel injection system, servicing Página 29 de 58 supply via fuel pump relay Check Oxygen Sensor (O2S) heating Oxygen Sensor (O2S) Behind Three Catalytic Converter (TWC) - G130- Page 24- Check Oxygen Sensor (O2S) Oxygen Sensor control after Three Catalytic Converter (TWC) Page 24-...
  • Page 752 Fuel injection system, servicing Página 30 de 58 When replacing, erase learned values adapt Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338- Page 24- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 753 Fuel injection system, servicing Página 31 de 58 24-18 Connector Gold plated terminals Black, 6-pin Heated Oxygen Sensor (HO2S) -G39- Oxygen Sensor (O2S) Heater -Z19- Component location: Right on underside of vehicle http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 754 Fuel injection system, servicing Página 32 de 58 24-19 20 - Heated Oxygen Sensor (HO2S) - G39-*, 50 Nm Component location: In front exhaust pipe Remove install with Oxygen Sensor (O2S) ring wrench 3337 Grease only threads with G 052 112 A3 hot bolt paste (ant-seize...
  • Page 755 Fuel injection system, servicing Página 33 de 58 Heated Oxygen Sensor (HO2S) Page 24-38 Check Oxygen Sensor (O2S) Oxygen Sensor control before Three Catalytic Converter (TWC) Page 24- Check aging Heated Oxygen Sensor (HO2S) Page 24-150 When replacing, erase learned values adapt Motronic...
  • Page 756 Fuel injection system, servicing Página 34 de 58 J338- Page 24- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 757 Fuel injection system, servicing Página 35 de 58 24-20 21 - Junction piece 22 - Non- return valve Observe installation position White connector faces towards Secondary Injection (AIR) Solenoid Valve - N112- /Intake Manifold Change- Over Valve - N156- 23 - Vacuum line From vacuum...

  • Page 758: Página 36 De 58

    Fuel injection system, servicing Página 36 de 58 Connector Black, 2-pin Mark connector component before pulling connector off. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 759 Fuel injection system, servicing Página 37 de 58 24-21 26 - Wiring harness With connectors for fuel injectors 27 - Fuel rail Disassembling assembling Page 24-26 CAUTION! Part numbers are for reference only. Always check with your Parts. Dept. for the latest parts information.
  • Page 760 Fuel injection system, servicing Página 38 de 58 24-22 Intake manifold, disassembling assembling 1 - Intake manifold Removing installing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 15 2 - Seal Always replace 3 - Bearing Intake Manifold Change-...
  • Page 761 Fuel injection system, servicing Página 39 de 58 24-23 7 - 23 Nm 8 - Vacuum union From brake booster 9 - Vacuum union From fuel system leak detectionpump: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 10 - Vacuum union From fuel...
  • Page 762 Fuel injection system, servicing Página 40 de 58 24-24 12 - Throttle Valve Control Module - J338-* No cable cam plate accelerator cable as this is an system Checking Page 24-59 When replacing, erase learned values adapt Motronic Engine Control Module (ECM) - J220- to...
  • Page 763 Fuel injection system, servicing Página 41 de 58 14 - Vacuum line Intake Manifold Change- Over Valve - N156- Page 24-12 item 2 15 - Vacuum actuator Intake Manifold Change- Over Valve - N156- Checking Page 24-117 Positioning lever change- over barrel Check...
  • Page 764 Fuel injection system, servicing Página 42 de 58 24-25 17 - Change- over barrel 18 - Gasket Observe installation position replace if damaged Vacuum reservoir Intake Manifold Change- Over Valve - N156- Removing installing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code...
  • Page 765 Fuel injection system, servicing Página 43 de 58 24-26 Fuel rail, disassembling assembling 1 - Fuel rail 2 - 8 Nm 3 - Return line Blue or with blue marking Secure with spring- type clips Check seated securely To fuel delivery unit: Repair...
  • Page 766 Fuel injection system, servicing Página 44 de 58 fuel filter: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 767 Fuel injection system, servicing Página 45 de 58 24-27 Connecting hose Black Check seated securely Secure with spring- type clips For air shrouding of fuel injectors intake hose Page item 5 6 - O-ring Replace Before installing moisten with clean engine 7 - Fuel injectors...
  • Page 768 Fuel injection system, servicing Página 46 de 58 24-97 When replacing, erase learned values adapt Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338- Page 24- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 769 Fuel injection system, servicing Página 47 de 58 24-28 8 - Retaining clip Ensure seated correctly at fuel injector and fuel rail 9 - Retaining clip Check seated securely 10 - Vacuum line To non- return valve/intake manifold junction piece 11 - Fuel pressure regulator...
  • Page 770 Fuel injection system, servicing Página 48 de 58 24-29 Air cleaner assembly, disassembling assembling 1 - Connecting hose Black crankcase breather Check seated securely Press together at front release From breather housing cylinder head cover Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF;...
  • Page 771 Fuel injection system, servicing Página 49 de 58 N79- crankcase breather http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=... 12/2/2005...
  • Page 772 Fuel injection system, servicing Página 50 de 58 24-30 4 - Connector Black, 2-pin Positive Crankcase Ventilation (PCV) Heating Element - N79- Check Positive Crankcase Ventilation (PCV) Heating Element - N79- voltage supply between terminals 1 and 2 with ignition switched Specification: min.
  • Page 773 Fuel injection system, servicing Página 51 de 58 Page 24- , item 5 Mass Air Flow (MAF) sensor - G70-* with Intake Air Temperature (IAT) sensor -G42-* Sensor connector terminals are gold plated Check Mass Flow (MAF) sensor Page 24-52 Check Intake Air Temperature...
  • Page 774 Fuel injection system, servicing Página 52 de 58 24-31 7 - Connector Black, 5-pin Terminals from sensor connector are gold plated 8 - Air cleaner upper part 9 - 6 Nm 10 - 10 Nm Air intake connecting piece cold air intake 12 - Air cleaner...
  • Page 775 Fuel injection system, servicing Página 53 de 58 24-32 16 - Intake hose Check seated securely Secure with spring-type clips To Throttle Valve Control Module -J338 17 - Vacuum line From intake manifold/Evaporative Emissions (EVAP) canister purge regulator valve junction piece Press together at front to release...
  • Page 776 Fuel injection system, servicing Página 54 de 58 24-33 Safety precautions CAUTION! When performing repair work, especially due to the confined conditions in the engine well, pay attention to the following: Route all types of lines (e.g. for fuel, hydraulics, Evaporative Emissions (EVAP) system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
  • Page 777 Fuel injection system, servicing Página 55 de 58 24-34 To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be noted: WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection.
  • Page 778 Fuel injection system, servicing Página 56 de 58 24-35 If the engine is to be turned at starter speed, without starting: - Remove fuse 29 (fuel pump) from fuse holder. Note: Removing fuse 29 interrupts the voltage supply to the fuel injectors. - Remove engine cover.
  • Page 779 Fuel injection system, servicing Página 57 de 58 24-36 Rules for cleanliness When working on the fuel supply/fuel injection system, pay careful attention to the following 5 Rules of Cleanliness: Thoroughly clean all unions and the adjacent areas before disconnecting. Place parts that have been removed on a clean surface and cover.
  • Page 780 Fuel injection system, servicing Página 58 de 58 24-37 Technical data Engine code Idling check idle speed 640 TO 720 Motronic Engine Control Module (ECM) -J220- System designation Motronic ME7.1.1 Part number Parts catalog Governed speed rpm from approx. 6500 idle speed check Page 24-125 Not adjustable...
  • Page 781 Components, checking Página 1 de 87 24-38 Components, checking Heated Oxygen Sensor (HO2S), checking Note: The vehicle must be raised to gain access to the Oxygen Sensor (O2S) connector. Only gold plated terminals may be used to repair the terminals in the Oxygen Sensor (O2S) connectors.
  • Page 782 Components, checking Página 2 de 87 24-39 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be switched off.
  • Page 783 Components, checking Página 3 de 87 24-40 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 784 Components, checking Página 4 de 87 24-41 Note: The Oxygen Sensor (O2S) heating may be switched on or off depending on the operating conditions of the engine, therefore the display in display zone 2 may show "Htg.bC.ON" or alternating from "Htg.bC.ON" to "Htg.bC.OFF". - Press button.
  • Page 785 Components, checking Página 5 de 87 24-42 Checking resistance - Check sensor heater wire resistance at connector terminals 3 and 4 to Oxygen Sensor (O2S). Specification: 2.5 to 10.0 room temperature). If the specification is not obtained: - Replace Oxygen Sensor (O2S) 1, Bank 1 before Three Way Catalytic Converter (TWC) -G39- Page 24-19...
  • Page 786 Components, checking Página 6 de 87 24-43 Checking voltage supply - Connect multimeter to measure voltage at terminals 3 and 4 (connector to Motronic Engine Control Module (ECM) -J220-) using adapter cables from VAG 1594. - Start engine and run at idle speed.
  • Page 787 Components, checking Página 7 de 87 24-44 - Check wiring for open circuit between test box and 6-pin connector according to Electrical Wiring Diagrams. Terminal 4 and socket 5 Wire resistance: max. 1.5 If the specification is obtained: - Check wire for open circuit between 6-pin connector terminal 3 and Fuel Pump (FP) -J17- referring to Electrical Wiring...
  • Page 788 Components, checking Página 8 de 87 24-45 Oxygen Sensor (O2S) heating for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, checking Note: The vehicle must be raised to gain access to the Oxygen Sensor (O2S) connector. Only gold plated terminals may be used when servicing Oxygen Sensor (O2S) connector terminals 3 and 4.
  • Page 789 Components, checking Página 9 de 87 24-46 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 790 Components, checking Página 10 de 87 24-47 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 791 Components, checking Página 11 de 87 24-48 Note: The Oxygen Sensor (O2S) heating may be switched on or off depending on the operating conditions of the engine, therefore the display in display zone 4 may show "Htg.aC.ON" or alternating from "Htg.aC.ON" to "Htg.aC.OFF". - Press the button.
  • Page 792 Components, checking Página 12 de 87 24-49 Checking resistance - Check sensor heater wire resistance at connector terminals 1 and 2 to Oxygen Sensor (O2S). - Specification: 6,4 to 47,5 room temperature). If the specification is not obtained: - Replace Oxygen Sensor (O2S) 2, Bank 1 after Three Way Catalytic Converter (TWC) -G130- Page...
  • Page 793 Components, checking Página 13 de 87 24-50 Checking voltage supply - Connect multimeter to measure voltage at terminals 1 and 2 (connector to Motronic Engine Control Module (ECM) -J220-) using adapter cables from VAG 1594. - Start engine and run at idle speed.
  • Page 794 Components, checking Página 14 de 87 24-51 - Check wiring for open circuit between test box and 4-pin connector referring to Electrical Wiring Diagrams. Terminal 2 and socket 63 Wire resistance: max. 1.5 If the specification is obtained: - Check wire for open circuit between 4-pin connector terminal 1 and Fuel Pump (FP) relay -J17- referring to Electrical Wiring...
  • Page 795 Components, checking Página 15 de 87 24-52 Mass Air Flow (MAF) sensor - G70- , checking Note: Only gold plated terminals may be used to service terminals in the Mass Air Flow (MAF) sensor connector. Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable...

  • Page 796: Display Zone 2

    Components, checking Página 16 de 87 24-53 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 797 Components, checking Página 17 de 87 24-54 Test sequence - Connect VAG 1551 Scan tool ( or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 798 Components, checking Página 18 de 87 24-55 - Switch off ignition. If the specification is achieved but an Mass Air Flow (MAF) related Diagnostic Trouble Code (DTC) is registered in Diagnostic Trouble Code (DTC) memory: - Check voltage supply for Mass Air Flow (MAF) sensor -G70- Page 24-55 If the specification is not obtained:...
  • Page 799 Components, checking Página 19 de 87 24-56 - Connect multimeter to measure voltage at connector terminal 2 and engine Ground (GND). - Start engine and run at idle speed. Specification: 11.0 to 15.0 V - Switch off ignition. If no voltage is present: - Check wire for open circuit between 5-pin connector terminal 2 and Fuel Pump (FP) -J17-...
  • Page 800 Components, checking Página 20 de 87 24-57 If no voltage is present: - Check signal and Ground (GND) wires for Mass Air Flow (MAF) sensor Page 24-57 Checking signal and Ground (GND) wires for Mass Air Flow (MAF) sensor - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment;...
  • Page 801 Components, checking Página 21 de 87 24-58 - Additionally check wiring for short to one another, to vehicle Ground(GND) and to battery positive. Specification: If no wiring malfunction is detected: - Replace Mass Air Flow (MAF) sensor -G70- Page 24-30 , item 6 .
  • Page 802 Components, checking Página 22 de 87 24-59 Throttle Valve Control Module -J338-, checking Note: Only gold plated terminals may be used to service the terminals in the connector of the Throttle valve control module -J338-. Components of Throttle valve control module - J338-: Throttle drive (power accelerator actuation) -G186-, Angle sensor -1- for throttle drive (power accelerator actuation) -G187- and...
  • Page 803 Components, checking Página 23 de 87 24-60 Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 804 Components, checking Página 24 de 87 24-61 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 805 Components, checking Página 25 de 87 24-62 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with "Address word" 01. ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12 Indicated on display:...
  • Page 806 Components, checking Página 26 de 87 24-63 - Depress accelerator slowly to wide open throttle position and observe angles displayed in display zones 1 and 2: Percentage display in display zone 1 must increase evenly. Full tolerance range 3 to 93% is not always displayed.
  • Page 807 Components, checking Página 27 de 87 24-64 - Switch off ignition. If the display does not indicate as described: - Disconnect 6-pin connector from Throttle Valve Control Module - J338- (arrow). Checking resistance - Measure resistance from throttle valve drive between terminals 3 and 5 Specification: 1.0 to 5.0 If the specification is not obtained:...
  • Page 808 Components, checking Página 28 de 87 24-65 - Read readiness code Page 01-146 . If DTC memory has been erased or Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive (B+), readiness code must be generated again Page 01-149 If the specification is obtained: - Check voltage supply of Throttle Valve Control Module -J338- and wiring to control module...
  • Page 809 Components, checking Página 29 de 87 24-66 - Read readiness code Page 01-146 . If DTC memory has been erased or Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive (B+), readiness code must be generated again Page 01-149 Checking voltage supply and wiring to control module - Connect multimeter to measure voltage at...
  • Page 810 Components, checking Página 30 de 87 24-67 - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment, Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wiring for open circuit between test box socket and connector referring to Electrical...
  • Page 811 Components, checking Página 31 de 87 24-68 - Additionally check wiring for short to one another, to vehicle Ground(GND) and to battery positive. Specification: If no wiring malfunction is detected: - Check Motronic Engine Control Module (ECM) - J220- voltage supply Page 24-163 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory...
  • Page 812 Components, checking Página 32 de 87 24-69 Engine Coolant Temperature (ECT) sensors -G62- and -G2-, checking Note: The Motronic Engine Control Module (ECM) -J220- will use a replacement value for an engine start (start temperature replacement value) as soon as there is a Diagnostic Trouble Code (DTC) stored in the DTC memory, which affects the Engine Coolant Temperature (ECT) sensor -G62-.
  • Page 813 Components, checking Página 33 de 87 24-70 Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 814 Components, checking Página 34 de 87 24-71 Test sequence Note: Only gold plated terminals may be used when servicing the sensor connector terminals. - Connect VAG 1551 Scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with "Address word"...
  • Page 815 Components, checking Página 35 de 87 24-72 If the specification is not obtained: - Check according to following table: Cause Continuation of Display check Approx. - Open circuit or Page 24-74 short to 42.0 C positive Approx. Short to Ground Page 24-76 (GND) 136.0 C...
  • Page 816 Components, checking Página 36 de 87 24-73 - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. If the display does not indicate as described: - Replace Engine Coolant Temperature (ECT) sensor -G62- / Engine Coolant Temperature (ECT) sensor -G2- Page 24-16...
  • Page 817 Components, checking Página 37 de 87 24-74 Continuation of check when display reads approx. -42.0 C - Disconnect 4-pin connector (arrow( from Engine Coolant Temperature (ECT) sensor -G62- / Engine Coolant Temperature (ECT) sensor -G2-. - Jumper connector terminals 3 and 4 using adapter cables from VAG 1594 and observe display.
  • Page 818 Components, checking Página 38 de 87 24-75 - Replace Engine Coolant Temperature (ECT) sensor -G62- / Engine Coolant Temperature (ECT) sensor -G2- Page 24-16 , item 14 . - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Read readiness code...
  • Page 819 Components, checking Página 39 de 87 24-76 Continuation of check when display reads approx. 136.0 C - Disconnect 4-pin connector (arrow) from Engine Coolant Temperature (ECT) sensor -G62- / Engine Coolant Temperature (ECT) sensor -G2-. If display jumps to approx. -42.0 - Press button.
  • Page 820 Components, checking Página 40 de 87 24-77 If display remains at approx. 136.0 C: - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. - Check wiring referring to Electrical Wiring Diagrams Page 24-77 Checking wiring...
  • Page 821 Components, checking Página 41 de 87 24-78 - Check wiring for open circuit between test box and 4-pin connector referring to Electrical Wiring Diagrams. Terminal 3 and socket 93 Terminal 4 and socket 108 Wire resistance: max. 1.5 - Additionally check wiring for short to one another, to vehicle Ground (GND) and to battery positive.
  • Page 822 Components, checking Página 42 de 87 24-79 Scale A shows resistance values for temperature range 0 to 50 C and scale B the values for temperature range 50 to 100 C. Examples: 30 C is in range A and corresponds to a resistance of 1.5 to 2.0 k 80 C is in range B and corresponds to a resistance of...
  • Page 823 Components, checking Página 43 de 87 24-80 If there is no Diagnostic Trouble Code (DTC) in the wiring and the resistance measurement values are OK.: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 824 Components, checking Página 44 de 87 24-81 Intake Air Temperature (IAT) sensor -G42-, checking Note: The Intake Air Temperature (IAT) sensor - G42- is a component part of the Mass Air Flow (MAF) sensor -G70- and cannot be replaced individually. http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 825 Components, checking Página 45 de 87 24-82 Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 826 Components, checking Página 46 de 87 24-83 Test sequence Note: Only gold plated terminals may be used to service the terminals in the Intake Air Temperature (IAT) sensor. - Connect VAG 1551 Scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with "Address word"...
  • Page 827 Components, checking Página 47 de 87 24-84 If the specification is not obtained: - Check according to following table: Cause Continuation of Display check Approx. - Open circuit or Page 24-86 short to 37.0 C positive Approx. Short to Ground Page 24-88 (GND) 126.0 C...
  • Page 828 Components, checking Página 48 de 87 24-85 - Spray sensor (arrow) with commercial chilling agent while observing temperature value. Temperature value must decrease. - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition.
  • Page 829 Components, checking Página 49 de 87 24-86 Continuation of check when display reads approx. -37.0 C - Disconnect 5-pin connector (arrow) from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-. - Jumper connector terminals 1 and 3 using adapter cables from VAG 1594 and observe display.
  • Page 830 Components, checking Página 50 de 87 24-87 - Replace Mass Air Flow (MAF) sensor -G70- Page 24-30 , item 6 . - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Read readiness code Page 01-146 .
  • Page 831 Components, checking Página 51 de 87 24-88 Continuation of check when display reads approx. 126.0 C - Disconnect 5-pin connector (arrow) from Mass Air Flow (MAF) sensor -G70- with Intake Air Temperature (IAT) sensor -G42-. If display jumps to approx. -42.0 - Press button.
  • Page 832 Components, checking Página 52 de 87 24-89 If display remains at approx. 126.0 C: - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. - Check wiring referring to Electrical Wiring Diagrams Page 24-89 Checking wiring...
  • Page 833 Components, checking Página 53 de 87 24-90 - Check wiring for open circuit between test box and 5-pin connector referring to Electrical Wiring Diagrams. Terminal 1 and socket 26 Terminal 3 and socket 27 Wire resistance: max. 1.5 - Additionally check wiring for short to one another, to vehicle Ground (GND) and to battery positive.
  • Page 834 Components, checking Página 54 de 87 24-91 Scale A shows resistance values for temperature range 0 to 50 C and scale B the values for temperature range 50 to 100 C. Examples: 30 C is in range A and corresponds to a resistance of 1.5 to 2.0 k 80 C is in range B and corresponds to a resistance of...
  • Page 835 Components, checking Página 55 de 87 24-92 If there is no Diagnostic Trouble Code (DTC) in the wiring and the resistance measurement values are OK.: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 836 Components, checking Página 56 de 87 24-93 Engine Speed (RPM) Sensor -G28-, checking Function 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.
  • Page 837 Components, checking Página 57 de 87 24-94 - Measure sensor resistance between connector terminals 2 and 3 to sensor. Specification: 480 to 1000 - Check sensor for short circuit between terminals 1 and 2 as well as 1 and 3. Specification: If the specifications are not obtained:...
  • Page 838 Components, checking Página 58 de 87 24-95 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wiring for open circuit between test box and 3-pin connector referring to Electrical Wiring Diagrams.
  • Page 839 Components, checking Página 59 de 87 24-96 If no wiring malfunction is detected: - Remove sensor and check sensor wheel for secure mounting, 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.
  • Page 840 Components, checking Página 60 de 87 24-97 Fuel injectors, checking Special tools, materials and equipment VAG 1526 or Fluke 83 Hand multimeter or VAG 1715 multimeter VAG 1527 LED test light VAG 1594 Adapter set VAG 1598/31 test box Electrical Wiring Diagrams Test requirements The fuses must be OK.
  • Page 841 Components, checking Página 61 de 87 24-98 Fuel Pump (FP) Relay -J17- must be OK., checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations Checking activation - First check activation of fuel injectors via Output Diagnosis Test Mode (DTM) Page 01-100 If activation is OK: - Remove intake manifold: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 842 Components, checking Página 62 de 87 24-99 Checking resistance of fuel injectors - Check resistance of fuel injectors between terminals. Specification: 13.0 to 19.0 Note: The resistance value is valid when measured at approx. 20 C. The resistance value increases at higher temperatures.
  • Page 843 Components, checking Página 63 de 87 24-100 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory 01-23 - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- again Page 24-182 - Read readiness code Page 01-146 .
  • Page 844 Components, checking Página 64 de 87 24-101 Checking activation and voltage supply - Connect VAG 1527 LED test light to connector terminals of fuel injector to be tested using cables from VAG 1594. - Operate starter and check activation for fuel injector. LED must flicker - Switch off ignition.
  • Page 845 Components, checking Página 65 de 87 24-102 - Check wiring for open circuit between test box and the 2-pin connector for fuel injectors referring to Electrical Wiring Diagrams. Fuel injector 1: Terminal 2 and socket 96 Fuel injector 2: Terminal 2 and socket 112 Fuel injector 3: Terminal 2 and socket 88...
  • Page 846 Components, checking Página 66 de 87 24-103 If there is no Diagnostic Trouble Code (DTC) in the wiring and the resistance measurement values are OK.: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 847 Components, checking Página 67 de 87 24-104 Fuel injectors, checking for leaks quantity injected Special tools equipment 1348/3 Remote control 1348/3-2 Adapter VAG 1594 A Adapter 1598/31 Test box VAG 1602 Calibration tester http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 848 Components, checking Página 68 de 87 24-105 Test requirements The fuel pressure must be in order, checking Page 24-110 Test sequence - Remove intake manifold: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group - Remove fuel rail complete (fuel lines remain connected) Page 24-26 Checking for leaks...
  • Page 849 Components, checking Página 69 de 87 24-106 If the fuel loss is greater: - Replace faulty fuel injector Page 24-27 , item Observe the following when installing fuel injectors: Replace O-rings on all fuel injectors and moisten them lightly with clean engine oil. Insert fuel injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
  • Page 850 Components, checking Página 70 de 87 24-107 - Read readiness code Page 01-146 . If DTC memory has been erased or Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive (B+), readiness code must be generated again Page 01-149 Checking quantity injected - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment;...
  • Page 851 Components, checking Página 71 de 87 24-108 - Connect one terminal of fuel injector to be tested to engine Ground(GND) using adapter cables from VAG 1594. - Using adapter cables connect the second fuel injector terminal to remote control VAG 1348/3 with adapter cable VAG 1348/3-2.
  • Page 852 Components, checking Página 72 de 87 24-109 Observe the following when installing fuel injectors: Replace O-rings on all fuel injectors and moisten them lightly with clean engine oil. Insert fuel injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
  • Page 853 Components, checking Página 73 de 87 24-110 Residual pressure and fuel pressure regulator, checking Special tools equipment VAG 1318 Pressure gauge 1318/10 Adapter 1318/11 Adapter 1318/16 Hose adapter VAS 5024 Assembly tool for spring- type clips http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 854 Components, checking Página 74 de 87 24-111 Function The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure. The specification for the check is dependent upon the working pressure of the fuel pump. This is approx. 3.0 bar Test requirements Fuel pump delivery rate OK., checking: Repair Manual, 2.8 Liter VR6 4V Engine...
  • Page 855 Components, checking Página 75 de 87 24-112 Test sequence - Pull fuse No. 28 (for fuel pump) out of fuse holder. - Pull fuel supply hose -1- (black) off fuel rail and collect fuel that leaks out with a cloth. WARNING! Fuel system is under pressure! Before opening the system place...
  • Page 856 Components, checking Página 76 de 87 24-113 - Connect pressure gauge VAG 1318 with adapter, VAG 1318/10 to supply hose -1- and with adapter VAG 1318/11 and VAG 1318/16 hose adapter to supply line. - Open shut-off tap on pressure gauge.
  • Page 857 Components, checking Página 77 de 87 24-114 If the specification is not obtained: - Check delivery rate of fuel pump: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group If the specification is obtained: - Now check for leaks and holding pressure. Watch pressure drop on gauge.
  • Page 858 Components, checking Página 78 de 87 24-115 If the pressure does not drop: - Check fuel pump non-return valve: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 20 If the pressure drops again: - Open pressure gauge VAG 1318 shut-off tap (handle in direction of flow -arrow-).
  • Page 859 Components, checking Página 79 de 87 24-116 If the pressure drops again: - Check line connections, O-rings on fuel rail and fuel injectors for leaks. - Check pressure gauge for leaks. When the pressure gauge is removed after completing the test: - Remove fuse No.
  • Page 860 Components, checking Página 80 de 87 24-117 Intake Manifold Change-Over Valve -N156-, checking The check need only be performed when performance is poor. The change-over from long to short intake channels occurs at approx. 4400 rpm. Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable...
  • Page 861 Components, checking Página 81 de 87 24-118 Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051. VAG 1390 Hand vacuum pump Checking function - Start engine and run at idle speed.
  • Page 862 Components, checking Página 82 de 87 24-119 If the actuating element does not perform the change-over sequence: - Check activation of Intake Manifold Change Over Valve -N156- via Output Diagnosis Test Mode (DTM) Page 01-100 If activation is OK: - Connect scan tool. - Pull vacuum hose -1-off non-return valve - Connect hand vacuum pump VAG 1390 to non return valve -2-.
  • Page 863 Components, checking Página 83 de 87 24-120 If the change-over does not function as described: - Check change-over mechanics for freedom of movement. Move rods by hand. - Check vacuum pipes for correct connection. - Check vacuum system including vacuum reservoir.
  • Page 864 Components, checking Página 84 de 87 24-121 Intake Air system, leak testing Checking with engine leak detector spray G 001 800 A1 Note: The vacuum in the intake system will cause the leak detector spray to be drawn in with the unmetered air.
  • Page 865 Components, checking Página 85 de 87 24-122 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 866 Components, checking Página 86 de 87 24-123 Indicated on display: Read measured value block Input display group number XXX - Press buttons -0-, -0- and -1- for "Display group number 1" and confirm entry with -Q- button. Indicated on display: (1...4 display Read measured value block 1 zones)
  • Page 867 Components, checking Página 87 de 87 24-124 If the engine speed drops or the Oxygen Sensor control changes: - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. - Check sprayed areas of intake system for leaks and correct if necessary.
  • Page 868 Functions, checking Página 1 de 37 24-125 Functions, checking Idle speed check Note: Idle speed, ignition timing and CO content not adjustable. The idle speed is regulated to specification by the throttle valve positioner in conjunction with the DIS function. CO content regulated to specification by Oxygen Sensor control.
  • Page 869 Functions, checking Página 2 de 37 24-126 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 870 Functions, checking Página 3 de 37 24-127 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 871 Functions, checking Página 4 de 37 24-128 Indicated on display: (1 to 4 System in basic setting 1 display zones) Note: In the function "System in basic setting" the Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- is closed and the air conditioner compressor turned off.
  • Page 872 Functions, checking Página 5 de 37 24-129 - Check operating conditions in display zone 4: Specification: xx000 Significance of figures in 5 digit number block Page 01-240 - Check specified idle speed in display zone 2. Specification: 700 rpm - Check actual idle speed in display zone 1. Specification: 640 to 720 rpm - Press button.
  • Page 873 Functions, checking Página 6 de 37 24-130 - Check control module DTC memory again. - Repeat engine idle speed check. If the specifications are not obtained again: - Check Throttle Valve Control Module -J338- Page 24-59 - Check operating condition of engine Page 24- - Check intake air system for leaks (unmetered air)
  • Page 874 Functions, checking Página 7 de 37 24-131 Oxygen Sensor (O2S) and Oxygen Sensor control before Three Way Catalytic Converter (TWC), checking Note: The vehicle must be raised to gain access to the Oxygen Sensor (O2S) connector. Only gold plated terminals may be used to service the terminals in the Oxygen Sensor (O2S) connectors.
  • Page 875 Functions, checking Página 8 de 37 24-132 VAG 1598/31 test box Electrical Wiring Diagrams Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 876 Functions, checking Página 9 de 37 24-133 Functional check - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 877 Functions, checking Página 10 de 37 24-134 Note: The bits in display zone 1 will not be set to 1 until the Three Way Catalytic Converter (TWC) temperature rises above 380 C ( display groups 34, display zone 2). If the specification is not obtained: - Press button.
  • Page 878 Functions, checking Página 11 de 37 24-135 - Check Oxygen Sensor learned values at part load (multiple active) in display zone 2. Specification: -10.0 to 10.0% If the specifications are not obtained: - Press button. - Press buttons -0- and -6- for function "End output"...
  • Page 879 Functions, checking Página 12 de 37 24-136 If the displays in display zones 1 and 2 fluctuate: - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. If one or both of the displays in zones 1 and 2 display a value constantly: - Press...
  • Page 880 Functions, checking Página 13 de 37 24-137 - Road test vehicle to remove possible contaminates on Oxygen Sensor (O2S) and repeat check. Observe the valid safety precautions when performing a road test Page 24-33 If the specifications in display zone 1 are not obtained even after a road test, or the value does not fluctuate by at least 2%: - Check Heated Oxygen Sensor (HO2S) for aging...
  • Page 881 Functions, checking Página 14 de 37 24-138 Checking wiring for Heated Oxygen Sensor (HO2S) - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected.
  • Page 882 Functions, checking Página 15 de 37 24-139 - Check wiring for open circuit between test box and 6-pin connector (to control module) referring to Electrical Wiring Diagrams. Terminal 1 and socket 70 Terminal 2 and socket 71 Terminal 5 and socket 51 Terminal 6 and socket 52 Wire resistance: max.
  • Page 883 Functions, checking Página 16 de 37 24-140 Oxygen Sensor (O2S) and Oxygen Sensor control after Three Way Catalytic Converter (TWC), checking Note: The vehicle must be raised to gain access to the Oxygen Sensor (O2S) connector. Only gold plated terminals may be used to service the terminals in the Oxygen Sensor (O2S) connectors.
  • Page 884 Functions, checking Página 17 de 37 24-141 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 885 Functions, checking Página 18 de 37 24-142 Functional check - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 886 Functions, checking Página 19 de 37 24-143 Note: The bits in display zone 1 will not be set to 1 until the Three Way Catalytic Converter (TWC) temperature rises above 380 C ( display groups 34, display zone 2) and a part load signal is recognized by the Motronic Engine Control Module (ECM) -J220-.
  • Page 887 Functions, checking Página 20 de 37 24-144 If the display in display zone 1 fluctuates: - Press button. - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. If the display in display zone 1 remains constantly at a value: - Press button.
  • Page 888 Functions, checking Página 21 de 37 24-145 - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Road test vehicle to remove possible residue on Oxygen Sensor (O2S) and repeat check. Observe the valid safety precautions when performing a road test Page 24-33 If the specifications in display zone 1 are not...
  • Page 889 Functions, checking Página 22 de 37 24-146 Check basic voltage of Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- - Remove protective cover (arrows) and disconnect 4-pin connector (black) -1- to Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- - Connect multimeter to measure voltage at terminals 3 and 4 (connector to ECM) using adapter...
  • Page 890 Functions, checking Página 23 de 37 24-147 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- again Page 24-182 - Read readiness code Page 01-146 .
  • Page 891 Functions, checking Página 24 de 37 24-148 Checking wiring for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness.
  • Page 892 Functions, checking Página 25 de 37 24-149 - Check wiring for open circuit between test box and 4-pin connector (to control module) referring to Electrical Wiring Diagrams. Terminal 3 and socket 68 Terminal 4 and socket 69 Wire resistance: max. 1.5 - Additionally check wires all for short to one another.
  • Page 893 Functions, checking Página 26 de 37 24-150 Heated Oxygen Sensor (HO2S), checking aging Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 894 Functions, checking Página 27 de 37 24-151 Selector lever must be in position "P" or "N" on vehicles with an automatic transmission. Exhaust system between Three Way Catalytic Converter (TWC) and cylinder head must be free of leaks. Engine Coolant Temperature (ECT) must be at least 85 C, display group 1, display zone 2.
  • Page 895 Functions, checking Página 28 de 37 24-152 Indicated on display: (1 to 4 System in basic setting 34 display zones) - Depress brake pedal and hold. - Depress accelerator down to wide open throttle position. Engine speed will be increased by Motronic Engine Control Module (ECM) -J220- to approx.
  • Page 896 Functions, checking Página 29 de 37 24-153 If the display does not indicate as described: - Road test vehicle to remove possible residue on Oxygen Sensor (O2S) and repeat check. Observe the valid safety precautions when performing a road test Page 24-33 If the display does not indicate as described again:...
  • Page 897 Functions, checking Página 30 de 37 24-154 Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130-, checking aging Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 898 Functions, checking Página 31 de 37 24-155 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 899 Functions, checking Página 32 de 37 24-156 Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -4- for function "Initiate basic setting" and confirm entry with -Q- button. Indicated on display: Basic setting Input display group number XXX - Press buttons -0-, -4- and -3- for "Display group number 43"...
  • Page 900 Functions, checking Página 33 de 37 24-157 - Depress and hold brake pedal and accelerator until display zone 4 displays specification "B1-P2 OK." - Release brake and accelerator pedals. - Press button. - Press buttons -0- and -6- for function "End output"...
  • Page 901 Functions, checking Página 34 de 37 24-158 Engine operating mode, checking Note: The check establishes whether Motronic Engine Control Module (ECM) -J220- recognizes the engine operating modes idling, overrun, part throttle, wide open throttle and enrichment. Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable...
  • Page 902 Functions, checking Página 35 de 37 24-159 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 903 Functions, checking Página 36 de 37 24-160 Part throttle: - Rev up evenly. As long as the engine is being revved up evenly, part throttle must be displayed Display: Part throt. Enrichment: - Floor accelerator pedal (onto throttle valve limit stop).
  • Page 904 Functions, checking Página 37 de 37 24-161 Wide open throttle: - Floor accelerator pedal (onto throttle valve limit stop). Full load must be displayed briefly Display: Full load Note: A road test may have to be performed to show "Full load" in display. Observe the valid safety precautions when performing a road test Page 24-33...
  • Page 905 Motronic Engine Control Module (ECM) -J220- Página 1 de 26 24-162 Motronic Engine Control Module (ECM) -J220- Function The Motronic Engine Control Module (ECM) -J220- regulates the injection, Throttle Valve Control Module -J338-, Oxygen Sensor control, ignition, knock regulation, Evaporative Emissions (EVAP) canister purge regulator valve, speed limitation via fuel injectors or Fuel Pump (FP) relay, camshaft timing adjustment as well as On...
  • Page 906 Motronic Engine Control Module (ECM) -J220- Página 2 de 26 24-163 Engine Control Module (ECM) voltage supply, checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 907 Motronic Engine Control Module (ECM) -J220- Página 3 de 26 24-164 Test requirements The fuses must be OK. The main fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off.
  • Page 908 Motronic Engine Control Module (ECM) -J220- Página 4 de 26 24-165 Fuel Pump (FP) -J17- must be OK, checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations Motronic Engine Control Module (ECM) Power Supply Relay -J271- must be OK., checking: Electrical Wiring Diagrams, Troubleshooting & Component Locations Alternator OK., checking: Electrical Wiring Diagrams, Troubleshooting &...
  • Page 909 Motronic Engine Control Module (ECM) -J220- Página 5 de 26 24-166 - Press buttons -0-, -0- and -4- for "Display group number 4" and confirm entry with -Q- button. Indicated on display: (1 to 4 display zones) Read measured value block 4 - Read figure displayed in display zone 2.

  • Page 910: Checking Voltage Supply Terminal

    Motronic Engine Control Module (ECM) -J220- Página 6 de 26 24-167 Checking voltage supply terminal 30 - Measure supply voltage between sockets 1 and 62, and 2 and 62 of test box using multimeter and adapter cables from VAG 1594: Specification: at least 11.5 V If the specification is not obtained: - Check wiring to fuse holder and Ground (GND)
  • Page 911 Motronic Engine Control Module (ECM) -J220- Página 7 de 26 24-168 Checking voltage supply terminal 15 - Measure supply voltage between test box sockets using multimeter and adapter cables from VAG 1594: Sockets 1 and 3 Sockets 1 and 21 Sockets 2 and 3 Sockets 2 and 21 - Switch on ignition.
  • Page 912 Motronic Engine Control Module (ECM) -J220- Página 8 de 26 24-169 If the specification is not obtained: - Check wiring to fuse holder and Ground (GND) connection of Motronic Engine Control Module (ECM) -J220- referring to Electrical Wiring Diagrams: Electrical Wiring Diagrams, Troubleshooting & Component Locations - Check wiring to Motronic Engine Control Module (ECM) Power Supply Relay -J271- referring to...
  • Page 913 Motronic Engine Control Module (ECM) -J220- Página 9 de 26 24-170 "Voltage supply open circuit," followup procedure All values learned by the Motronic Engine Control Module (ECM) - J220- and the basic setting values as well as the readiness code will be erased if the voltage supply is interrupted.
  • Page 914 Motronic Engine Control Module (ECM) -J220- Página 10 de 26 24-171 Work sequence Perform the following operations after interrupting voltage supply: - Switch ignition on for at least 10 seconds. - Switch off ignition. - Erase learned values and adapt Motronic Engine Control Module (ECM) -J220- again Page 24-182 - Perform idle speed check...
  • Page 915 Motronic Engine Control Module (ECM) -J220- Página 11 de 26 24-172 During the road test the following operating conditions must be fulfilled: Engine Coolant Temperature (ECT) must exceed 80 C . When the temperature is reached, the operating conditions Idling Part throttle Wide open throttle Overrun...
  • Page 916 Motronic Engine Control Module (ECM) -J220- Página 12 de 26 24-173 Motronic Engine Control Module (ECM) -J220-, replacing Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 917 Motronic Engine Control Module (ECM) -J220- Página 13 de 26 24-174 Removing Print out control module identification and thereby previous control module coding as follows: - Connect VAG 1551 Scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with "Address word"...
  • Page 918 Motronic Engine Control Module (ECM) -J220- Página 14 de 26 24-175 - Press retaining tab (arrow) to left and pull control module out. Installing - Place new control module into retaining frame. - Install control module connector and lock. - Check previous coding and coding of new control module Page 24-177 - Adapt new control module to...
  • Page 919 Motronic Engine Control Module (ECM) -J220- Página 15 de 26 24-176 Vehicles with an automatic transmission - Also adapt automatic transmission control module: Repair Manual, 5 Spd. Automatic Transmission 09A On Board Diagnostic (OBD); Repair Group 01 Continuation for all vehicles - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page...
  • Page 920 Motronic Engine Control Module (ECM) -J220- Página 16 de 26 24-177 Motronic Engine Control Module (ECM) J220-, coding Note: A 5-character code must always be displayed during the control module identification. Measured value block 125 indicates which control modules are connected via CAN- the Motronic Engine Control Module (ECM) J220- Page 01-267...
  • Page 921 Motronic Engine Control Module (ECM) -J220- Página 17 de 26 24-178 Work sequence - Connect VAG 1551 Scan tool (or VAG 1552). Then switch ignition on and select Motronic Engine Control Module (ECM) -J220- with "Address word" 01. ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 922 Motronic Engine Control Module (ECM) -J220- Página 18 de 26 24-179 - Enter relevant code number fo vehicle and confirm with -Q- button. Coding variations of Motronic Engine Control Module (ECM) -J220- Page 24-181 The control module identification and coding are 022906032BL MOTRONIC ME7.1.1 G 0006 shown on the display, e.g.: Coding 00032...
  • Page 923 Motronic Engine Control Module (ECM) -J220- Página 19 de 26 24-180 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 Diagnostic Trouble Code (DTC) s (gear change jolts, load change jerks, etc.) Increased fuel consumption...
  • Page 924 Motronic Engine Control Module (ECM) -J220- Página 20 de 26 24-181 Motronic Engine Control Module (ECM) -J220-, coding variations 1. position: 2. position: 3. position: 4. position: 5. position: vehicle emissions sensor CAN-bus transmission code code code code No coding No coding coding coding...
  • Page 925 Motronic Engine Control Module (ECM) -J220- Página 21 de 26 24-182 Motronic Engine Control Module (ECM) - J220- to Throttle Valve Control Module - J338-, matching Function First, old learned values are erased. This is necessary to set learned values, which may be at the limit, to a neutral (Diagnostic Trouble Code (DTC) position.
  • Page 926 Motronic Engine Control Module (ECM) -J220- Página 22 de 26 24-183 Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 927 Motronic Engine Control Module (ECM) -J220- Página 23 de 26 24-184 The throttle valve must not be soiled (carbon deposits). No Diagnostic Trouble Code (DTC)s must be stored in DTC memory Page 01-23 Coolant temperature must be 5 to 110 C display group 4, display zone 3.
  • Page 928 Motronic Engine Control Module (ECM) -J220- Página 24 de 26 24-185 Indicated on display: Adaption learned values have been erased - Press button. Indicated on display: Rapid data transfer HELP Select function XX - Press buttons -0- and -4- for function "Initiate basic setting"...
  • Page 929 Motronic Engine Control Module (ECM) -J220- Página 25 de 26 24-186 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...

  • Page 930: Página 26 De

    Motronic Engine Control Module (ECM) -J220- Página 26 de 26 24-187 To store the values: - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. Note: If the basic setting of the control module is aborted, the cause could be one of the following: The requirements have not been fulfilled.
  • Page 931 Additional signals, checking Página 1 de 40 24-188 Additional signals, checking Vehicle Speed Signal, checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 932 Additional signals, checking Página 2 de 40 24-189 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 933 Additional signals, checking Página 3 de 40 24-190 Test sequence Note: To check the vehicle speed signal, the vehicle must be driven. To do this a second person is necessary. WARNING! Secure test equipment to rear seat and operate it from this position. - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word"...
  • Page 934 Additional signals, checking Página 4 de 40 24-191 Indicated on display: (1 to 4 Read measured value block 5 display zones) - Road test vehicle with a 2nd person to observe display. Observe the valid safety precautions when performing a road test Page 24-33 - Observe figure displayed in...
  • Page 935 Additional signals, checking Página 5 de 40 24-192 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Connect multimeter to measure voltage between test box sockets 1 (Ground) and 54 (vehicle speed signal) using adapter cables from VAG 1594.
  • Page 936 Additional signals, checking Página 6 de 40 24-193 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Read readiness code Page 01-146 . If DTC memory has been erased or Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive (B+), readiness code must be generated again Page 01-149...
  • Page 937 Additional signals, checking Página 7 de 40 24-194 A/C compressor signal, checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 938 Additional signals, checking Página 8 de 40 24-195 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. Selector lever must be in position "P"...
  • Page 939 Additional signals, checking Página 9 de 40 24-196 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 940 Additional signals, checking Página 10 de 40 24-197 - Switch on air conditioning system. - Select lowest temperature and highest blower speed. The display in display zone 3 must change to: A/C-High. The display in display zone 4 must change to: Compr.
  • Page 941 Additional signals, checking Página 11 de 40 24-198 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected. - Check wiring for open circuit between test box sockets 40 and 41 and air conditioning system referring to Electrical Wiring Diagrams.
  • Page 942 Additional signals, checking Página 12 de 40 24-199 Signal from Clutch Vacuum Vent Valve Switch -F36-, checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 943 Additional signals, checking Página 13 de 40 24-200 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 944 Additional signals, checking Página 14 de 40 24-201 Indicated on display: Read measured value block Input display group number XXX - Press buttons -0-, -6- and -6- for "Display group number 66" and confirm entry with -Q- button. Indicated on display: (1...4 display Read measured value block 66 zones)
  • Page 945 Additional signals, checking Página 15 de 40 24-202 - Disconnect 4-pin connector from Clutch Vacuum Vent Valve Switch -F36- (arrow). - Measure resistance between switch terminals 2 and 3. Specification: Clutch not depressed: max. 1.5 Clutch depressed: If the specifications are not obtained: - Replace Clutch Vacuum Vent Valve Switch -F36-.
  • Page 946 Additional signals, checking Página 16 de 40 24-203 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory 01-23 - Read readiness code Page 01-146 . If DTC memory has been erased or Motronic Engine Control Module (ECM) -J220- was disconnected from battery positive (B+), readiness code must be generated again Page 01-149...
  • Page 947 Additional signals, checking Página 17 de 40 24-204 If the specification is obtained: - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected.
  • Page 948 Additional signals, checking Página 18 de 40 24-205 If there is no Diagnostic Trouble Code (DTC) in the wiring and the resistance measurement values are OK.: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 949 Additional signals, checking Página 19 de 40 24-206 Brake Light Switch -F- and Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47- signal, checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously...
  • Page 950 Additional signals, checking Página 20 de 40 24-207 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 951 Additional signals, checking Página 21 de 40 24-208 - Press buttons -0- and -8- for function "Read measured value (data) block" and confirm entry with -Q- button. Indicated on display: Read measured value block Input display group number XXX - Press buttons -0-, -6- and -6- for "Display group number 66"...
  • Page 952 Additional signals, checking Página 22 de 40 24-209 - Disconnect 4-pin connector from Brake Light Switch -F- and Brake Pedal Switch (cruise control/Diesel Direct Fuel Injection) -F47- - Measure resistance between terminals 1 and 4 of switch. Specification: Brake pedal not depressed: Brake pedal depressed: max.
  • Page 953 Additional signals, checking Página 23 de 40 24-210 If the specifications are obtained: - Connect multimeter to measure voltage between terminal 1 and Ground (GND). Specification: at least 11.5 V If the specification is not obtained: - Check wiring connections to fuse holder for open circuit referring to Electrical Wiring Diagrams.
  • Page 954 Additional signals, checking Página 24 de 40 24-211 If the specification is obtained: - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected.
  • Page 955 Additional signals, checking Página 25 de 40 24-212 If there is no Diagnostic Trouble Code (DTC) in the wiring and the resistance measurement values are OK.: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 956 Additional signals, checking Página 26 de 40 24-213 Transmission Range signal, checking Vehicles with an automatic transmission The Motronic Engine Control Module (ECM) -J220- receives the following information from the transmission control module: Driving range selected (selector lever in 2/3/4/R/D) No transmission range selected (selector lever in P or N) http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 957 Additional signals, checking Página 27 de 40 24-214 Special tools and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 958 Additional signals, checking Página 28 de 40 24-215 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, it must be turned off.
  • Page 959 Additional signals, checking Página 29 de 40 24-216 Test sequence - Connect VAG 1551 Scan tool (or VAG 1552) and select engine electronics control module with "Address word" 01. Engine must be running at idle speed: ((VAG 1551 and Motronic Engine Control Module (ECM) -J220-, connecting and selecting Page 01-12...
  • Page 960 Additional signals, checking Página 30 de 40 24-217 - Press buttons -0- and -6- for function "End output" and confirm entry with -Q- button. - Switch off ignition. If the specifications are not obtained: - Check CAN-bus matching resistor Page 24- - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page...
  • Page 961 Additional signals, checking Página 31 de 40 24-218 Cruise Control System (CCS), checking Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 962 Additional signals, checking Página 32 de 40 24-219 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.
  • Page 963 Additional signals, checking Página 33 de 40 24-220 Indicated on display: Read measured value block Input display group number XXX - Press buttons -0-, -6- and -6- for "Display group number 66" and confirm entry with -Q- button. Indicated on display: (1 to 4 Read measured value block 66 display zones) Vehicles with an automatic...
  • Page 964 Additional signals, checking Página 34 de 40 24-221 Continuation for all vehicles - Check specification for switch position of CCS operating switch in display zone 4. Test requirements Display zone 4 Switch B at "OFF", in xxxxxxx0 detent Switch B at "OFF", in xxxxxx0x detent or not in detent...
  • Page 965 Additional signals, checking Página 35 de 40 24-222 If the specifications are not obtained: - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) - J220- remains disconnected.
  • Page 966 Additional signals, checking Página 36 de 40 24-223 CAN-bus, checking Function The Motronic Engine Control Module (ECM) -J220- communicates with other CAN-bus compatible control modules via a CAN-bus. These CAN-bus-capable components are connected by a pair of twisted CAN-bus wires (CAN high and CAN low) and exchange information (messages).
  • Page 967 Additional signals, checking Página 37 de 40 24-224 Special tools, materials and equipment VAG 1551 Scan tool (or VAG 1552) with VAG 1551/3 adapter cable Note: All functions which could previously be performed with VAG 1551/1552 can also be performed with the VAS 5051.
  • Page 968 Additional signals, checking Página 38 de 40 24-225 Test requirements The CAN-bus On Board Diagnostic (OBD) has detected a Diagnostic Trouble Code (DTC). Test sequence - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to Motronic Engine Control Module (ECM) -J220-.
  • Page 969 Additional signals, checking Página 39 de 40 24-226 If the resistance measurement is not within the specified range: - Replace Motronic Engine Control Module (ECM) -J220- Page 24-173 - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Erase learned values and adapt Motronic...
  • Page 970 Additional signals, checking Página 40 de 40 24-227 If the resistance value is within the specified range: - Repair Diagnostic Trouble Code (DTC): Electrical Wiring Diagrams, Troubleshooting & Component Locations - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23 - Erase learned values and adapt Motronic...
  • Page 971 Ignition system, servicing Página 1 de 51 28-1 Ignition system, servicing General notes on ignition system Note: Only the components which specifically relate to the ignition system are dealt with here. For the other components of the injection and ignition system Repair Group 24.
  • Page 972 Ignition system, servicing Página 2 de 51 28-2 If the engine starts, runs for a short period and then stops, after troubleshooting, repairs or component tests, then the malfunction may lie with the Immobilizer which is blocking the Engine Control Module (ECM). In such cases the DTC memory must be checked and, if necessary, the control module adapted.
  • Page 973 Ignition system, servicing Página 3 de 51 28-3 Ignition system components, removing installing Note: Engine Control Module (ECM) with connectors Page 24-14 item 8 . 1 - Connector Black, 4-pin Mark connector component before pulling connector off. 2 - Ignition coil with power output...
  • Page 974 Ignition system, servicing Página 4 de 51 3 - Control housing camshaft timing adjustment Removing installing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code (s): BDF; Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 975 Ignition system, servicing Página 5 de 51 28-4 4 - Bracket For Knock sensor (KS) 1 - G61- connection Component location: on right of cylinder head 5 - 10 Nm 6 - 3-pin connector Black Gold plated terminals 7 - Knock Sensor (KS) 1 - G61-*...
  • Page 976 Ignition system, servicing Página 6 de 51 8 - 20 Nm Torque setting influences function of knock sensor http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 977 Ignition system, servicing Página 7 de 51 28-5 9 - Exhaust camshaft timing adjuster Marking: Turn engine over only when camshaft timing adjuster installed With sensor wheel for Camshaft Position (CMP) Sensor 2 -G163- camshaft timing adjuster has been removed, after installing check...
  • Page 978 Ignition system, servicing Página 8 de 51 Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code (s): BDF; Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 979 Ignition system, servicing Página 9 de 51 28-6 60 Nm plus additional 90 turn Replace Terminal surface of sensor wheel on bolt head must be dry for assembly remove install, use a 32 open jaw wrench camshaft as a counter- hold: Repair Manual, 2.8...
  • Page 980 Ignition system, servicing Página 10 de 51 Repair Group 12 - Seal Replace Camshaft Position (CMP) Sensor 2 -G163-* exhaust camshaft Sensor connector terminals are gold plated Checking Page 28-16 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 981 Ignition system, servicing Página 11 de 51 28-7 14 - 10 Nm Connector Black, 3-pin Sensor connector terminals are gold plated Mark connector component before pulling connector off. Camshaft Position (CMP) Sensor - G40-* intake camshaft Sensor connector terminals are gold plated Checking Page...
  • Page 982 Ignition system, servicing Página 12 de 51 28-8 17 - Knock Sensor (KS) 2 - G66-* Component location: Between cyl. 4 and cyl. 6 Terminal surfaces between knock sensor cylinder block must be free of corrosion, dirt and grease. Sensor connector terminals are gold...
  • Page 983 Ignition system, servicing Página 13 de 51 Mark direction of rotation before removing (installation position) Installing: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code (s): BDF; Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 984 Ignition system, servicing Página 14 de 51 28-9 20 - Intake camshaft adjuster Marking: Turn engine over only when camshaft timing adjuster installed With sensor wheel for Camshaft Position (CMP) Sensor 2 -G163- camshaft timing adjuster has been removed, after installing check timing:...
  • Page 985 Ignition system, servicing Página 15 de 51 Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code (s): BDF; Repair Group http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 986 Ignition system, servicing Página 16 de 51 28-10 Camshaft Adjustment Valve 1 (exhaust) - N318-* exhaust camshaft Mark connector component before pulling connector off. Check camshaft timing adjustment: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 15 Valve -1- camshaft...
  • Page 987 Ignition system, servicing Página 17 de 51 timing adjustment: Repair Manual, 2.8 Liter VR6 4V Engine Mechanical, Engine Code(s): BDF; Repair Group 15 http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 988 Ignition system, servicing Página 18 de 51 28-11 23 - Spark plug, 25 Nm Remove install with spark plug wrench 3122 B Type electrode Page 28- http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=... 12/2/2005...
  • Page 989 Ignition system, servicing Página 19 de 51 28-12 Safety precautions To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be noted: WARNING! When performing repair work, especially due to the confined conditions in the engine well, pay attention to the following: Route all types of lines (e.g.
  • Page 990 Ignition system, servicing Página 20 de 51 28-13 If the engine is to be turned at starter speed, without starting: - Remove fuse 29 from fuse holder. Note: Removing fuse 29 interrupts the voltage supply to the fuel injectors. - Remove engine cover. - Disconnect connectors from ignition coils 1...6.
  • Page 991 Ignition system, servicing Página 21 de 51 28-14 Observe following if test and measuring instruments are required during a test drive: Test and measuring instruments must be secured to 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...
  • Page 992 Ignition system, servicing Página 22 de 51 28-15 Test Data, Spark plugs Engine code 1-5-3-6-2-4 Firing order Spark plugs VW No. 101 000 062 AB Manufacturer's designation PZF R5D-11 Electrode gap max. 1.1 mm Torque setting 25 Nm Remove and install spark plugs with plug wrench 3122 B http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Next&type=repair&id=...
  • Page 993 Ignition system, servicing Página 23 de 51 28-16 Camshaft Position (CMP) Sensor, checking Note: Only gold-plated terminals may be used to service the terminals in the Camshaft Position (CMP) Sensor connector. Special tools, materials and equipment VAG 1526 or Fluke 83 Hand multimeter or VAG 1715 multimeter VAG 1594 adapter set VAG 1598/31 test box...
  • Page 994 Ignition system, servicing Página 24 de 51 28-17 Checking sequence for intake camshaft Camshaft Position (CMP) Sensor -G40- - Disconnect 3-pin connector from Camshaft Position (CMP) Sensor -G40-, -1-. Note: Mark connector and component before disconnecting. - Connect multimeter to measure voltage at terminals 1 (positive) and 3 (Ground) of Camshaft Position (CMP) Sensor connector...
  • Page 995 Ignition system, servicing Página 25 de 51 28-18 If no voltage is present: - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) remains disconnected.
  • Page 996 Ignition system, servicing Página 26 de 51 28-19 - Additionally check wires for short to one another. Specification: If no wiring malfunction is detected and voltage was present between terminals 1 and 3: - Replace Camshaft Position (CMP) Sensor -G40- Page 28-7 , item 16 .
  • Page 997 Ignition system, servicing Página 27 de 51 28-20 - Read readiness code Page 01-146 . If DTC memory has been erased or Engine Control Module (ECM) was disconnected from battery positive, readiness code must be generated again Page 01-149 Checking sequence for Camshaft Position (CMP) Sensor 2 -G163- - Disconnect 3-pin connector -2- from Camshaft Position (CMP) Sensor 2 -G163-.
  • Page 998 Ignition system, servicing Página 28 de 51 28-21 If no voltage is present: - Remove wiper arms and cowl panel: Repair Manual, Electrical Equipment; Repair Group 92 - Connect VAG 1598/31 test box to control module wiring harness. Engine Control Module (ECM) remains disconnected.
  • Page 999 Ignition system, servicing Página 29 de 51 28-22 If no wiring malfunction is detected and voltage was present between terminals 1 and 3: - Replace Camshaft Position (CMP) Sensor 2 - G163- Page 28-6 , item 13 . - Check DTC memory, repair malfunctions if necessary and then erase DTC memory Page 01-23...
  • Page 1000 Ignition system, servicing Página 30 de 51 28-23 Ignition coil with power output stage, checking Note: The ignition coils and power output stage are combined into a single component and cannot be replaced separately. Special tools, materials and equipment VAG 1526 or Fluke 83 Hand multimeter or VAG 1715 multimeter VAG 1527 LED test light VAG 1594 adapter set...
  • Page 1001 Ignition system, servicing Página 31 de 51 28-24 Test requirements The fuses must be OK. The battery voltage must be at least 11.5 V. All electrical accessories, e.g. lights and rear window defroster must be switched off. If the vehicle is equipped with air conditioning, this must be switched off.

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