Code Control Module (Function 07) : Page 01-10

Code Control Module (function 07) Page 1 of 3
01-62
Code Control Module

(function 07)
- Connect VAS5051 tester or VAG1551 scan tool
and select control module for engine electronics
using "address word" 01 Page 01-10 . Ignition
must remain switched on.
Rapid data transfer HELP When indicated on display

Select function XX
- Press buttons -0- and -7- to select "Code control module" and press -
Q- button to confirm input.
Code Control Module Q When indicated on display

Enter code numbers XXXXX (0-32000)
- Enter control module coding according to code table Page 01-64 .
Clarification of coding
XX Country/Exhaust
X Drive/Additional Functions
X Transmission
X Vehicle model
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.FU06.01.6 11/21/2002
01-63
Coding example
07551 USA LEV 1) (emissions regulations),
Front Wheel Drive (FWD) with ESP 2) , 5
speed Automatic transmission, Audi A4
1) LEV: Abbreviation for Low Emission Vehicle
2)ASR/ESP: Abbreviation for Anti-Slip

Regulation/Electronic Stability Program
- Confirm input using the -Q- button.
4B0906018M 1.8 L R4/5VT G 0002 VAG1551 Scan Tool (ST) display indicates control module identification,
Coding 16501 WSC 12345
e.g
- Press button.
Rapid data transfer HELP Indicated on display (function selection)

Select function XX
01-64
Coding table
Country / Exhaust 07 USA LEV (emissions regulation)

Drive / Additional Functions 5 Front Wheel Drive (FWD) with ASR/ESP
7 All Wheel Drive (AWD) with Electronic Stability Program (ESP)
Transmission 0 5 speed manual transmision
5 Automatic transmission 01V
Vehicle model 1 Audi A4
Readiness code Page 1 of 35
01-67
Readiness code
The readiness code appears as an 8-digit display
in measuring value block 086, display field 1.
Each of the 8 digits is allocated to a specific
exhaust related system.
During a test sequence which must be performed

completely, On Board Diagnostic (OBD) checks
the function of each of these systems and then
changes the character assigned to it in the 8-digit
indication from "1" to "0" once test has been
performed successfully.
When the readiness code is generated after a

successfully completed test sequence, it reads "0
0 0 0 0 0 0 0" (measuring value block 086,
display field 1).
If a single test is completed entirely, but indicated

as "not OK", a DTC will be stored in DTC
memory. Check DTC Memory Page 01-16 .
01-68
Readiness code is returned to"0 1 1 0 1 1 0 1"

if:
DTC memory was erased,
Voltage supply to ECM was cut off (e.g.

connector disconnected, battery disconnected)
a new Engine Control Module (ECM) was

installed
In this case, the readiness code must be re-

generated Page 01-73 .
Note:
During driving operation in various load

conditions, exhaust relevant tests are performed
by the control module and the readiness code is
generated on its own. In this case, however, the
concluding control possibilities are not available,
meaning that it will not be indicated whether the
vehicle is free of malfunctions upon transfer to
the customer.
01-69
Read readiness code
Test sequence

using "address word" 01 Page 01-10 . Ignition
must remain switched on.

Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block" and
press -Q- button to confirm input.
Read measuring value block Q When indicated on display

Enter display group number XXX
- Press buttons -0-, -8- and -6- to select "display group number 086" and
Read Measuring Value Block 86 When indicated on display

1 2 3 4
- Check readiness code in display field 1
Specification: 0 0 0 0 0 0 0 0
01-70
Display fields
1 2 3 4
Display group 086: Readiness code
Display 00000000 XXXXXXXX XXXXXXXX
Indicated Ready-Bits individual tests carried out individual tests carried out
completed tests
Functional range 1 = not completed 1 = not completed 1 = not completed
0 = completed 0 = completed 0 = completed

Specified value 00000000 XXXXXXXX XXXXXXXX
Note Significance of readiness code Page 01-71
Note for display field 1:
Display field 1 is the most important. This indicates which system was checked via On Board Diagnostic (OBD) since the last
time DTC memory was erased or a new control module was implemented. Once DTC memory is erased, all testable values
are set to "1", after the test is performed successfully, the values are set to "0".
01-71
X X X X X X X X Notes for display group 086, display field 1

Diagnostic of catalytic converter
Indication 0 = test was performed

Indication 1 = test was not performed (generate readiness code Page 01-73 )
Indication always 0
EVAP system

Secondary air system

Indication always 0
Oxygen sensors

Oxygen sensor heating
Indication always 0
Note:
Readiness code is not generated until all indications in display field 1 display "0"
01-72
Once the specified value "0 0 0 0 0 0 0 0" is

reached in display field 1:
- Press button.

Select function XX
- Check DTC memory as a control measure Page 01-16 (there must
not be any DTCs stored)
If specified value is not obtained:
- Generate readiness code Page 01-73 .
01-73
Readiness code, generating
Special Tools and Equipment
VAG1788/10 RPM adjuster
Requirements
Vehicle stationary
Vehicles with automatic transmission Selector lever in P or N.

Electrical consumers switched off (radiator fan must NOT run during
test).
A/C switched off.
Coolant temperature at least 80 C Display group 004, display field

3. Important: Drive engine warm via road test if possible.
Note:
If, during a work step, the test result is indicated as "OK" immediately after
selecting a display group, the test has already been carried out and it is
OK to continue on to the next work step.
01-74
Work step 1: Check DTC Memory
Test requirement:
Engine not running, ignition switched on.

using "address word" 01 Page 01-10 .

Select function XX
- Press buttons -0- and -2- to select "Check DTC memory" and press -Q-
button to confirm input.
X malfunctions recognized! Number of stored DTCs or "No DTC recognized" will be indicated on
display.
If a DTC is stored:
- Repair malfunction, erase DTC memory. Road test vehicle and then
check DTC memory as a control measure.
If no DTCs are stored:
- Press button.
01-75
Work step 2: Erase DTC Memory
Test requirement:

Select function XX
- Press buttons -0- and -5- to select "Erase DTC memory" and press -Q-
Note:
When DTC memory is erased, readiness code is reset and must therefore
be re-generated.
Rapid data transfer When indicated on display

DTC Memory is erased!
- Press button.
01-76
Work step 3: Adapt throttle valve control

module to Engine Control Module (ECM)
Test requirement:

Select function XX
- Press buttons -0- and -4- to select "Initiate basic setting" and press -Q-
Basic Setting Q When indicated on display

System in basic setting 60 When indicated on display

1 2 3 4
- Check specified values in display fields 3 and 4
01-77
Display fields
1 2 3 4
Display group 060: Adaptation of throttle valve control module
Display xx % xx % x ---
Indicated Throttle Throttle Adaptation step counter Adaptation condition
valve angle valve angle
(angle (angle
sensor 1) sensor 2)
Functional 0 to 8 ADP in progress
range
ADP OK
ERROR
Specified 3 to 93 % 97 to 3 % 8 ADP OK
value
Note After adaptation, the adaptation step If "ERROR." is displayed:
counter reaches the number 8 (it is OK for Check DTC memory Page
numbers to be skipped). 01-16 .
If specified value is not

obtained: Note, Page 24-
126
Different numbers are shown in display field 3 during adaptation that represent the current adaptation condition. It is not
particularly important how the adaptation step counter (display field 3) behaves during adaptation, but rather that display field
4 indicates the specification "ADP OK" after adaptation.
If specified value "ADP OK" is obtained:
- Press -C- button.
01-78
Work step 4: Kick down function, adapting1)
1) Only vehicles with automatic transmission
Test requirement:


1 2 3 4
Note:
There will be a prompt: "Operate kickdown".
- Depress accelerator pedal completely, past kick down point, and hold
down.
Note:
During adaptation of the kick down point, the VAG1551 will display "Kick
down ADP in progress". After successful adaptation of the kick down
point, the VAG1551 will display "Kick down ADP OK".
- Check specified value in display field 4:
01-79
Display fields
1 2 3 4
Display group 063: Kick down function, adapting
Display xx % xx % Kick ---
down
Indicated Sensor 1 for Sensor 2 for Kick Adaptation condition
down
Pedal Pedal
position position
Functional Kick operate
range down
ADP in progress
ADP OK
ERROR
Specified value 12 to 97 % 4 to 49 % Kick ADP OK
down
Note If "ERROR." is displayed: Check DTC memory Page
01-16 .
"ERROR" can be indicated, for example, if the accelerator pedal is not immediately pressed in response to a request by the
tester or if the accelerator pedal is released while adaptation is running despite the fact that adaptation is not yet complete. In
both cases, "Basic Setting" must be exited and the adaptation must be performed again.
- Press -C- button.
01-80
Work step 5: Check operating condition of

oxygen sensor control
- Start engine (for a vehicle with manual

transmission: engage clutch).
Note:
After starting engine, it may be necessary to

select the Engine Control Module (ECM) again
using "address word" 01 and the function "Initiate
basic setting" using "04".
- Install VAG1788/10 RPM adjuster on accelerator

pedal and raise engine speed to 2000 RPM.
Test requirement:
Engine running at 2000 RPM.


1 2 3 4
- Check oxygen sensor status in display fields 1 and 2.
Note:
A few minutes may pass until a diagnostic result is reached.
01-81
Display fields
1 2 3 4
Display group 030: Oxygen sensor status
Display XXX XXX
Indicated Oxygen sensor status, bank 1, sensor 1 Oxygen sensor status, bank 2, sensor 1
Functional range 0 = off 0 = off
1 = on 1 = on
Specified value 111 110
Significance of 3 digit indications in display group 030

X X X Display fields 1 and 2
X Oxygen sensor control: 0= not active; 1 = active
X Operational readiness of oxygen sensor: 0= not active; 1 = active
X Condition of oxygen sensor heater: 0= not active; 1 = active
Note:
The first position of the 3 digit indication (heating) fluctuates between 0 and 1 at certain operation points.
Oxygen sensor control of oxygen sensor behind catalytic converter (bank 1, sensor 2) is not active without engine load,
meaning that the third position of the 3-digit display is 0.
- Do not start test until indication in display field 1
has reached "111" at least once and indication in

display field 2 has reached "110" at least once.
01-82
Work step 6: Diagnostic of oxygen sensor

aging before catalytic converter
Test requirement:
Engine continues to run at 2000 RPM.


1 2 3 4
Note:
01-83
Display fields
1 2 3 4
Display group 034: Oxygen sensor aging diagnostic, oxygen sensor before catalytic converter (bank 1)
Display xxxx/min xxx C x.x s ---
Indicated Engine speed Exhaust Period duration Oxygen sensor Diagnostic condition
(RPM) temperature before Catalytic converter
Functional Test OFF
range
Test ON
B1-S2 OK
B1-S2 not OK
Specified 2000 RPM more than 350 0.0 to 1.0 s B1-S2 OK
value C
Note If "B1-S1 not OK" is displayed:
Check DTC memory Page 01-16 .
If specified value "B1-S1 OK" is obtained:
- Press -C- button.
01-84
Work step 7: Diagnostic of operational

readiness of oxygen sensor behind catalytic
converter
Test requirement:


1 2 3 4
01-85
Display fields
1 2 3 4
Display group 036: Operational readiness of oxygen sensor behind catalytic converter (bank 1)
Display x.xxx V ---
Indicated Oxygen sensor voltage Bank 2, Diagnostic condition
sensor 1
Functional Test OFF
range
Test ON
B1-S2 OK
B1-S2 not OK
Specified value 0.100 to 0.950 V B1-S2 OK
Note If "B1-S2 not OK" is displayed: Check DTC memory
Page 01-16
If specified value B1-S2 OK" is obtained:
- Press -C- button.
01-86

control system
Test requirement:


1 2 3 4
01-87
Display fields
1 2 3 4
Display group 037: Diagnostic of oxygen sensor control system (Bank 1)
Display xxx % x.xxx volts xxx ms ---
Indicated Load Oxygen sensor Oxygen sensor correction value Diagnostic condition
voltage Bank 2, between bank 1, sensor 1 and bank 1,
sensor 1 sensor 2
Functional Test OFF
range
Test ON
System OK
System not OK
Specified 12 to 0.100 to 0.950 V -150 to 150 ms System OK
value 30 %
Note If "System not OK" is displayed:
Check DTC memory Page 01-
16
If specified value "Syst. OK" is obtained:
- Press -C- button.
01-88
Work step 9: Diagnostic of catalytic converter
Test requirement:


1 2 3 4
- Check specified values in display fields 2 and 4:
Note:
Catalytic converter diagnostic lasts approx. 60 seconds.
01-89
Display fields
1 2 3 4
Display group 046: Diagnostic of catalytic converter (bank 1)
Display xxxx/min xxx C x.x ---
Indicated Engine speed Exhaust Measurement Diagnostic condition
(RPM) temperature
Catalytic converter -
conversion
Functional Test OFF
range
Test ON
Cat B1 OK
Cat B1 not OK
Specified 2000 RPM more than 0.0 to 0.2 Cat B1 OK
value 430 C
Note If "Cat B1 not OK" is displayed: Check DTC
memory Page 01-16 . If no DTCs are stored,
replace catalytic converter.
If specified value "Cat B1 OK" is obtained:
- Press -C- button.
01-90
Work step 10: Diagnostic of Secondary Air

Injection (AIR) system
- Remove VAG1788/10 RPM adjuster and leave

engine running at idle.
Test requirement:
Engine running at idle:
Note:
During diagnostic of the Secondary Air Injection

(AIR) system, the Secondary Air Injection (AIR)
pump will run for several seconds.


1 2 3 4
01-91
Display fields
1 2 3 4
Display group 077: Secondary Air Injection (AIR) system diagnostic (Bank 1)
Display xxxx/min xx.x g/s xx.x g/s ---
Indicated Engine speed Air Air mass Secondary air Diagnostic condition
(RPM) mass system
Functional Test OFF
range
Test ON
System OK
System not OK
Aborted
Specified FWD: 740 to 860 2 to 5 4 to 10 g/s System OK
value RPM g/s
AWD: 800 to 920

RPM
Note If "System not OK" is displayed: Check DTC
memory Page 01-16
- Press -C- button.
01-92
Work step 11: Diagnostic of tank ventilation

valve
Test requirement:


1 2 3 4
Note:
If test is not initiated or if indication switches from "Test ON" to "Test

OFF", depress accelerator pedal briefly, test will be repeated.
01-93
Display fields
1 2 3 4
Display group 070: Diagnostic of tank ventilation valve
Display xx % xx % ---
Indicated Degree tank Oxygen Diagnostic condition
ventilation valve is sensor control
opened
Diagnostic
value
Functional Test OFF
range
Test ON
TVV OK
TVV not OK
Aborted
Specified 0 to 99 % -7.0 to 7.0 % TVV OK
value
Note If "TVV not OK" is displayed: Check DTC memory Page 01-
16 . Check Evaporative Emission (EVAP) canister purge
regulator valve -N80- Page 24-107
If specified value "TVV OK" is obtained:
- Press -C- button.
01-94
Work step 12: Diagnostic of tank seal
Test requirements:
Fuel filler cap opened briefly (to reduce

pressure).


1 2 3 4
Note:
Test lasts approx. 90 seconds.
When the diagnostic of tank seal is performed several times in a row,
the fuel filler cap must be opened briefly before each test to release
pressure.
01-95
Display fields
1 2 3 4
Display group 071: Diagnostic of tank seal
Display --- --- --- ---
Indicated Condition Reed- DTC System condition Diagnostic condition
Terminal message
Functional Reed open Small leak System test Test OFF
range
Reed closed Large leak Measurement Test ON
END System OK
Measurement
System not OK
Aborted
Specified Reed open --- END System OK
value Measurement
Note If "System not OK" is displayed: Check DTC
memory Page 01-16
- Press button.

Select function XX
Work step 13: Read readiness code
- Read readiness code Page 01-69 .
Read Measuring Value Block (function 08) Page 1 of 2
01-65
Read Measuring Value Block

(function 08)
Test requirements:
Coolant Temperature at least 80 C.
Electrical consumers switched off (radiator

fan must NOT run during test).
A/C switched off.
Test sequence

using "address word" 01 Page 01-10 . Engine
must run at idle.

Select function XX
Read measuring value block Q When indicated on display

- Enter desired three digit display group number and confirm by pressing
-Q- button.
01-66
Note:
Which display group should be chosen depends

on current function and component tests.
Read Measuring Value Block 0 Indicated on display for display group 000
1 2 3 4 5 6 7 8 9 10
Read Measuring Value Block 1 Indicated on display (example) for display group 001
1 2 3 4
Note:
Display can be printed out on the paper roll when printer is switched
on.
To switch to a different display group, proceed as follows:
Display group VAG1551 Scan Tool VAS5051 tester

Higher Press button -3- Press button.
Lower Press button -1- Press button.
Basic setting (function 04) Page 1 of 5
01-66
Basic setting (function 04)

With ignition on and engine at standstill, the
following operations can be performed using
"function 04", basic setting:
Adapt throttle valve control module to Engine

Control Module (ECM) Display group 060(
Page 24-125 )
Vehicles with automatic transmission:

Adaptation of kick down function of accelerator
pedal position sensor to ECM Display group
063 ( Page 24-145 )
With engine running, the following operations

can be performed using basic setting:
Adaptation of oxygen sensor control Page

24-75
01-67
Test requirements for operations with engine

running:
No DTCs in DTC memory.

A/C switched off.
Vehicles with automatic transmission

Selector lever in P or N.
Test sequence
- Connect VAS5051 tester Page 01-7 and

select vehicle system "01 - Engine electronics".
Ignition must remain switched on for this.
or, depending on desired operation:
- Start engine.
Display on VAS5051:
- In selection -1-, click on the diagnostic function "04 - Basic setting".
01-68
Display on VAS5051:
1 - Enter display group Max. input value = 255

- Enter desired 3-digit display group number in button field -2- and press
-Q- button to confirm input.
Indicated on VAS5051 for display group 000:
1 - Display group 0
2 - Display field 1 2 3 4 5 6 7 8 9 10
Note:
After selecting display group number, the EVAP valve is closed and A/C
compressor switched off.
01-69
Indicated on VAS5051 for display group 001 to 255:
1 - Display group X System in basic setting

2 - Display field 1
Display field 2
Display field 3
Display field 4
Notes:
For display group number 000, measured values are displayed as a
decimal.
Display group VAS5051 tester

higher Press button.
Lower Press button.
- End function "04 - Basic setting" by pressing button.
01-70
Display group 000 (indicated values decimal)
Engine running at idle (Coolant Temperature not less than 80 C)
1 2 3 4 5 6 7 8 9 10 Display fields Specified represents

value
Adaptation value of mixture formation, partial 103 to 153 -10 to 10%
throttle
Adaptation value of mixture formation, closed throttle 78 to 178 -10 to 10%
(idle)
Control value of mixture formation 103 to 153 -10 to 10%
Adaptation value, torque loss at idle: 113 to 143 -3 to 3%
Torque at idle 106 to 189 -4.3 to 12.2%
Throttle valve angle 1 to 7 0.4 to 2.75%
Vehicle voltage 142 to 207 10 to 14.5 V
Engine speed (idle speed)
Front Wheel Drive (FWD) 74 to 86 740 to 860

RPM
All Wheel Drive (AWD) 76 to 88
760 to 880
RPM
Engine load (without consumers) 17 to 40 13 to 30%
Engine Coolant Temperature (requirement for basic setting) 180 to 205 80 to 105 C
Basic Setting (function 04) Page 1 of 5
01-66
Basic Setting (function 04)

With ignition on and engine at standstill, the
"function 04", basic setting:
Adapt throttle valve control module to Engine

Control Module (ECM) Display group 060 (
Page 24-142 )
Vehicles with automatic transmission:

Adaptation of kick down function of accelerator
pedal position sensor to ECM Display group
063 ( Page 24-161 )
With ignition on and engine running, the

basic setting:
Adaptation of oxygen sensor control Page

24-83
Troubleshooting via targeted activation and

deactivation of oxygen sensor control
Display group 099. For this, observe notes on
page Page 24-79 .
01-67
Test requirements for operations with engine

running:
No DTCs in DTC memory.

A/C switched off.
Test sequence

and select the control module for engine
electronics using "address word" 01 Page 01-
9.
Engine must run at idle for this.
- Check DTC Memory Page 01-15 . There must

not be any DTCs stored, repair malfunctions if
necessary, erase DTC memory, switch engine
off and start again, road test vehicle and check
DTC memory again as a control measure.
01-68
Depending on desired operation:
- Switch ignition on.
or
- Start engine.
Rapid data transfer HELP When indicated on display:

Select function XX
Initiate basic setting Q When indicated on display:

Input display group number XXX
- Input desired display group number.
Example:
Note:
After selecting this display group number, the EVAP valve is closed and
A/C compressor switched off.
Basic Setting 0 Q Indicated on display:

1 2 3 4 5 6 7 8 9 10
01-69
Notes:
For display group number 000, measured

values are displayed as a decimal.
Display can be printed out on the paper roll

when printer is switched on.
To switch to a different display group, proceed

as follows:
Display VAG1551 Scan VAS5051

group Tool (ST) tester
higher Press button -3- Press s
button.
Lower Press button -1- Press t
button.
- Let engine run at idle for a few minutes, coolant

temperature at least 80 C.
- If specified values are obtained in all display

fields, press button.
Rapid data transfer HELP Indicated on display (function selection):

Select function XX
01-70
Display group 000 (indicated values decimal)
Engine running at idle (Coolant Temperature not less than 80 C)
1 2 3 4 5 6 7 8 9 10 Display fields Specified represents
value
Adaptation value of mixture preparation, bank 2 77 to 179 -10 to 10 %
Adaptation value of mixture preparation, bank 1 77 to 179 -10 to 10 %
Control value of mixture preparation, bank 2 115 to 141 -10 to 10 %
(road test vehicle if outside of tolerance)

Control value of mixture preparation, bank 1 115 to 141 -10 to 10 %
(road test vehicle if outside of tolerance)

Adaptation value, torque loss at idle: 102 to 169 -5 to 8 %
Idle torque 102 to 154 -5.0 to 5.0 %
Throttle valve angle 0 to 8 0 to 3.0 %
Engine speed (idle speed)
Front Wheel Drive Vehicles 72 to 82 720 to 820 RPM
All-Wheel Drive Vehicles 63 to 73 630 to 730 RPM
Engine load (without consumers) 16 to 34 12 to 26 %

Engine Coolant Temperature (requirement for basic setting) 180 to 205 80 to 105 C
Central locking On Board Diagnostic (OBD) Page 1 of 55
01-69
Central locking On Board

Diagnostic (OBD)
General Information
The new generation of central locking is capable

of On Board Diagnostic. Use of DTC memory,
Output Diagnostic Test Mode and Read
Measuring Value Block facilitates the search for
malfunctions. The central locking system
variation can also be coded using the VAG1551
Scan Tool (ST).
Central locking has two pneumatic circuits. For

central locking without keyless entry, the first
circuit controls only the fuel filler flap; for central
locking with the keyless entry system, the first
circuit controls both the fuel filler flap and the
driver-side door. The second circuit controls all
remaining locking points.
On the safety-version of central locking, if the

driver-side (or passenger-side door) is unlocked
with a single command, then only that door and
the first pneumatic circuit are opened. If there is
another unlocking command within 5 seconds,
the second pneumatic circuit is also triggered
and the whole vehicle is unlocked.
If the rear lock cylinder is triggered only once, all

doors will remain locked. The rear lid (or tailgate)
will automatically re-lock itself after about 5
seconds.
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD04.01.3 11/20/2002
Interior lighting will gradually increase in intensity

until fully illuminated (within about 1.5 seconds)
when unlocking (fades off when locking).
01-70
The control of the luggage compartment lighting

proceeds from the central locking pump to the
rear lid (or tailgate) contact switch. The lighting
will be switched off while the rear lid is open
when a certain speed threshold is surpassed
(about 5 km/h) or after 10 minutes.
The new remote transmitter now uses radio

frequency. For vehicles using the radio frequency
remote locking system, the receiver is integrated
into the central locking pump. The remote locking
antenna is integrated into the wiring harness.
If no doors (or the rear lid) have been opened

within 60 seconds after the central locking
system is triggered via radio frequency, central
locking automatically relocks everything.
If the anti-theft alarm system is armed, central

locking cannot be opened via internal buttons.
All vehicles with an anti-theft system are

equipped with an ultrasonic interior monitoring
system. This could be an interior monitor of the
1st generation (without OBD) or of the 2nd
generation (with OBD). All that is necessary is
the proper coding of the central locking system
page 01-91 .
Confirmation can be received from central

locking as to whether the alarm system has been
armed while locking the doors. The confirmation
can be signalled by means of a short anti-theft
horn signal or by a brief flashing of the

emergency flashers. Central locking can also be
coded to give no confirmation at all.
Activation of keyless entry can be signalled by a

flashing of the emergency flashers.
01-71
Central Locking On Board Diagnostic

(OBD), initiating
Requirements
Power supply and fuses for relevant system

OK
Electrical Wiring Diagrams, Troubleshooting &

Component Locations binder
VAG1551 Scan Tool (ST) connected page

01-1
Notes:
If the display remains blank, check VAG1551

voltage supply according to wiring diagram,
The Scan Tool (ST) HELP button can provide

additional operating instruction.
The button is used to advance through the

program sequence.
If an incorrect entry is made, press the -C-

button to escape.
- Switch printer on by pressing PRINT button

(indicator lamp in button lights up).
- Press button -1- to select "Rapid data transfer"

operating mode 1.
Rapid data transfer HELP Indicated on display

Insert address word XX
01-72
Address word for central locking: 35
- Press buttons -3- and -5- to insert "Central

Locking" address word 35.
Rapid data transfer Q Indicated on display

35 - Central Locking
- Press -Q- button to confirm input.
Rapid data transfer Indicated on display

Scan Tool sends address word 35
Vehicles 1997:
8L0862257B CL-Pump, DWA, Func D04

After about 5 seconds, display indicates (for example):
Vehicles 1998 :

After about 5 seconds, display indicates (for example):
All vehicles:
- Press button.

Select function XX
01-73
Note:
A list of available functions is printed out when

the HELP button is pressed.
On Board Diagnostic (OBD) functions
The following functions are possible:
01 - Check Control Module Versions page 01-

85 .
02 - Check DTC Memory page 01-74 .
03 - Output Diagnostic Test Mode page 01-

88 .
05 - Erase DTC Memory page 01-137 .
06 - End Output page 01-139 .
07 - Code Control Module page 01-91 .
08 - Read Measuring Value Block page 01-

99 .
01-74
Check DTC Memory (scan tool function

02)
Note:
The DTC display information is updated only

when initiating the On Board Diagnostic (OBD)
program or when using the "Erase DTC Memory"
function 05.

Carrying out "Check DTC Memory" function

02

Select function XX
- Press buttons -0- and -2- to select "Check DTC Memory" function 02.

02 - Check DTC Memory
X DTC recognized The number of stored DTCs is indicated on display.
The stored malfunctions are displayed and printed out in sequence.

- Look up printed malfunctions in the DTC table and repair all
malfunctions page 01-76 .
01-75
No DTC recognized If the message "No DTC recognized" is displayed, the program can be
returned to the starting point by pressing the button.

Select function XX
If something else is displayed:
Scan tool operating instructions
- Erase DTC Memory (function 05) page 01-137 .

- End Output (function 06) page 01-139 .
- Disconnect VAG1551 Scan Tool (ST) from Data Link Connector (DLC).
01-76
Diagnostic Trouble Code (DTC) table, central locking
Notes:
The following table lists all the DTCs that can be recognized by the control module for central locking and printed out by
the VAG1551 Scan Tool (ST). The DTCs are listed in order according to their 5-digit numbers.
DTC 5-digit numbers appear only on the print-out from the scan tool.
Before replacing a component shown as malfunctioning, check wiring and connections to the component as well as the
Ground (GND) connections according to the relevant wiring diagram.
When a repair has been completed, check and then erase DTC memory using the VAG1551 Scan Tool (ST). After that,
the vehicle should be locked again (with key or remote control) and DTC memory checked again.
DTC memory records all static and sporadic malfunctions. When a malfunction occurs, it is first identified as a static
malfunction. If it does not occur again it is registered as a sporadic malfunction, and the letters "/SP" appear at the right of
the display.
When the ignition is switched on, all existing malfunctions are automatically re-classified as sporadic malfunctions and will
only be registered as static malfunctions if they still occur after testing.
Sporadic malfunctions which no longer occur after 50 driving cycles are erased automatically.
The three digit malfunction type number appearing next to the DTC is a data code which may be disregarded.
01-77
DTC
VAG 1551 scan tool Possible cause Corrective action
display
00955
Key 1
Key not matched - Perform remote transmitter coding procedure page
01-105
Adaptation limit Key operated more than 200 times
exceeded while out of range
00956
Key 2
01-105
00957
Key 3
01-105
00958
Key 4 - Perform remote transmitter coding procedure page
Key not matched
01-105
00991
Interior lighting
Short circuit to
Short circuit to in wiring - Repair wiring according to wiring diagram.
positive
01-78
DTC
display
01360
Open ATW Switch
Short circuit to Ground in wiring 1) - Repair wiring according to wiring diagram.
Short circuit to Door contact switch, driver's-side -
Ground Electrical Wiring Diagrams, Troubleshooting &
F2- faulty
- Check -F2- and replace if necessary.
01361
Close ATW Switch
Short circuit to Door contact switch, driver's-side -
Ground Electrical Wiring Diagrams, Troubleshooting &
F2- faulty
01362
Close Switch for
Tailgate-F124
Trunk lock alarm/central locking
Short circuit to Electrical Wiring Diagrams, Troubleshooting &
switch -F124- faulty
Ground Component Locations
1)A malfunction is stored if the Ground is connected for more than 1 min. (e.g. due to an incorrect operation of central
locking). Only initiate a repair if there is a proper complaint, otherwise erase DTC memory page 01-137 .
01-79
DTC
display
01363
Switch for CL; Drivers This indication can be caused by the system itself. - Ignore DTC and erase DTC memory
Door-F59 There is no malfunction of driver's door central locking page 01-137 .
system switch -F59-.
Incorrect Signal
01364
Switch for CL; This indication can be caused by the system itself. - Ignore DTC and erase DTC memory
Passenger Door- There is no malfunction of passenger door central page 01-137 .
F114 locking system switch -F114-.
Incorrect Signal
01365
Lock/Unlock
Short circuit to Ground in wiring 1) - Repair wiring according to wiring
Switch/Button Int. diagram.
Switch for interior lock, driver's side -E150- faulty
Short circuit to
Ground Electrical Wiring Diagrams,
Troubleshooting & Component
Locations binder
- Check -E150- and replace if

necessary.
1)A malfunction is stored if the Ground is connected for more than 1 min. (e.g. due to an incorrect operation of central
locking). Only initiate a repair if there is a proper complaint, otherwise erase DTC memory page 01-137 .
01-80
DTC
display
01365
Lock/Unlock
Short circuit Short circuit to Ground in wiring - Repair wiring according to wiring diagram.
Switch/Button Int.
Switch for interior lock, driver's side -E150-
Short circuit to B+ Electrical Wiring Diagrams, Troubleshooting
faulty
& Component Locations binder
- Check -E150- and replace if necessary.
01366
Open Via Crash Output Diagnostic Test Mode performed at - Erase DTC memory page 01-137 .
Signal airbag control module -J234-
- Repair wiring according to wiring diagram.
Short circuit to Airbag control module -J234- was triggered
Ground Electrical Wiring Diagrams, Troubleshooting
Short circuit in wiring between airbag control
& Component Locations binder
Open/short circuit to module and central locking control module
B+
01367
Switch on Via CL
Too little pressure in pneumatic lines - Check pneumatic lines for leaks.
Pump
Central locking pump faulty - Exchange central locking pump.
- Check all actuators of central locking system
and replace if necessary.
01-81
DTC
display
01368
Alarm Via Luggage Anti-theft system triggered by unauthorized - Erase DTC memory.
Compartment Switch opening of rear lid
- Replace -F123-.
Trunk lid alarm switch -F123- faulty
01369
Alarm Via Front Hood Anti-theft system triggered by unauthorized - Erase DTC memory.
Switch opening of hood
- Replace -F120-.
Hood alarm switch -F120- faulty
01370
Alarm Via Interior Anti-theft system triggered by control module for - Erase DTC memory.
Scanning ultra-sound sensors -J347-
- On Board Diagnostic (OBD) ultra-sound
Short circuit to Ground Control module for ultra-sound sensors -J347- interior monitoring page 01-108 .
faulty
- Repair wiring according to wiring
Short circuit in wiring between control module for diagram.
ultra-sound sensors and central locking control
module Electrical Wiring Diagrams,
Troubleshooting & Component Locations
binder
01371
Alarm Via Door Contact
Switch Driv. Side Anti-theft system triggered by unauthorized - Erase DTC memory.
opening of driver-side door
- Replace door contact switch -F2-.
Door contact switch, driver's side -F2- faulty
01-82
DTC
display
01372
Alarm Via Door Ctact. Anti-theft system triggered by unauthorized - Erase DTC memory.
Switch Rear PS opening of passenger-side and/or rear door(s)
- Replace contact switch -F3-, -F10-, -F11-.
Door contact switches -F3-, -F10-, -F11- faulty
01373
Alarm Via Radio Anti-theft system triggered by unauthorized - Erase DTC memory.
Ground Teminal removal of radio
- Provide Ground connection.
Ground connection for anti-theft system has an
open circuit
01374
Alarm Via Terminal
Anti-theft system triggered by unauthorized - Erase DTC memory.
15
starting (short circuiting)
- Repair wiring according to wiring diagram.
Short circuit between terminal 30 and 15
Electrical Wiring Diagrams,
binder
01-83
DTC
display
01384
Alarm via Broken Anti-theft alarm triggered by attempted - Erase DTC memory
Glass Sensor break-in at rear window
- Check and repair wiring and connectors per wiring
(rear window) Open in rear window defroster circuit diagram.
False alarm
- Replace rear window
Repair Manual, Body Exterior, Repair Group 64

01389
Tailgate Open Switch-
Short circuit to Ground in wiring - Repair wiring according to wiring diagram.
F124
Trunk lock alarm/central locking switch -
Short circuit to Electrical Wiring Diagrams, Troubleshooting &
F124- faulty
Ground Component Locations binder
- Replace -F124- in trunk lock.
01-84
DTC
VAG 1551 scan tool display Possible cause Corrective action
01403
Broken Glass Sensors Anti-theft alarm triggered by attempted - Erase DTC memory
break-in at one of the side windows
- Check and repair wiring and connectors
Open in circuit of one of the side per wiring diagram.
Broken glass sensor for rear left windows
side window -G183 Electrical Wiring Diagrams,
False alarm
or binder
Broken glass sensor for rear - Replace side window as necessary

right side window -G184
Repair Manual, Body Exterior, Repair
Group 64
65535
Control Module Malfunctioning - Replace control module.
01-85
Check Control Module Versions (scan

tool function 01)
Select function XX
- Press buttons -0- and -1- to select "Check Control Module Versions"
function 01.

01 - Check Control Module Versions
Vehicles 1997

Indicated on display
Explanation of display
8L0862257B: Part No. of central locking control modules

Central locking pump, Anti-theft system: component identification
D04: software version
Coding 12172: coding page 01-91
WSC 06812: dealership number
- Press button
01-86
Vehicles 1998
8L0862257BCL-Pump, DWA, Func D04

8L0862257B: Part No. of central locking control modules

Central locking pump, Anti-theft system: component identification
- Press button
01-87
All vehicles:
If one of these messages is indicated on the

display, perform On Board Diagnostic (OBD)
according to OBD instructions:

Control module does not answer
or

Error in communication link
or

K wire not switching to Ground
or

K wire not switching to B+
- Check wiring connections for Data Link Connector (DLC).
Electrical Wiring Diagrams, Troubleshooting & Component Locations

binder
Note:
If nothing appears on display:
Select function XX
01-88
Output Diagnostic Test Mode (scan tool

function 03)
Notes:
The Output Diagnostic Test Mode may only be

performed with the vehicle stationary and the
engine not running.
Any malfunctions identified by the Output

Diagnostic Test Mode must be checked and
repaired.
The output DTM activates the following elements

in sequence:
Emergency flashers and anti-theft horn (only for

vehicles equipped with anti-theft system)
Interior monitoring (activated even if interior

monitoring is not installed)
Emergency flashers and interior lights as a test

of the crash signal
01-89
Carrying out "Output Diagnostic Test Mode"

function 03

Select function XX
- Press buttons -0- and -3- to select "Output Diagnostic Test Mode"
function 03.

03 - Output Diagnostic Test Mode
Output Diagnostic Test Mode Indicated on display (emergency flasher and anti-theft horn are activated)
Create active alarm
- Press button.
Output Diagnostic Test Mode Indicated on display

Next final ctrl: operate
- Press button.
Output Diagnostic Test Mode Indicated on display (central locking control module sends a signal which
Activate interior monitoring
activates interior monitoring system)
Notes:
After activating interior monitoring, a system dependant waiting time of
30 seconds must be maintained.
If one alarm is activated, an entry into DTC memory of the control
module for central locking will be made "1370; alarm via interior
monitoring" as well as into control module for ultra-sound sensors
"alarm via sensor for anti-theft warning system; fl, fr, rl, rr".
Malfunctions must be checked and erased in DTC memory of the

respective control module.
01-90
- Press button.

Next final ctrl: operate
- Press button.
Output Diagnostic Test Mode Indicated on display (emergency flashers and interior lights are triggered)
Simulate crash signal
- Press button.
Notes:
The malfunction "1366; opening via crash-signal" is stored in DTC
memory of the control module for central locking.
Output Diagnostic Test Mode (DTM) must be repeated with airbag
control module. After performing output Diagnostic Test Mode (DTM)
of airbag control module, DTC "01366 opening via crash signal" will
also be stored in control module for central locking.
The malfunction must be checked in DTC memory of the control
module for central locking page 01-74 and erased page 01-137 .

END
- Press button.
The program is now back at its starting point.

Select function XX
01-91
Code Control Module (scan tool function

07)
With coding, different central locking variations

can be enabled for possible function/equipment
variations.
Central locking variations:
Central locking with anti-theft system
Central locking with remote control and anti-

theft system
Notes:
The basic functions of the central locking

system are listed in a standard code table
page 01-93 .
Further coding variations are possible at the

request of the customer page 01-94 .
Carrying out "Code Control Module" function

07

Select function XX
- Press buttons -0- and -7- to select "Code Control Module" function 07.

07 - Code Control Module
Code Control Module Indicated on display

Enter code number XXXXX (0-32000)
01-92
- Input coding of the central locking control

module with keypad (e.g. 16140 for central
locking with anti-theft/remote) vehicles1998 .
Code Control Module Q Indicated on display

Enter code number 16140 (0-32000)
8L0862257N CL pump, DWA, Func D12 - Indicated on display (control module identification with current coding)
Note:
Explanation of display page 01-85 .
- Press button

Select function XX
- Press buttons -0- and -6- to select "End Output" function 06.

06 - End Output

01-93
Standard code table
Vehicles 1997 (with Delta radio):
Vehicle type Central locking variation Standard coding

Audi A4 03468
Vehicle with central locking and anti-theft system
12172
Vehicle with central locking, anti-theft system and keyless entry
Vehicles 1998 (with Concert radio):
Vehicle type Central locking variation Standard coding

Audi A4 03340
16140
01-94
All vehicles:
In addition to basic coding, it is possible to offer

customers the following option:
Vehicle automatically locks upon reaching a

speed of about 15 km/h (10 mph) and unlocks
when the key is removed from the ignition
Optional code table
Vehicles 1997 (with Delta radio):
Vehicle type Central locking variation Optional coding

Audi A4 03500
12204
Vehicles 1998 (with Concert radio):
Vehicle type Central locking variation Optional coding

Audi A4 03372
16172
01-95
Notes:
Safety central locking (SCL) has the following

functions (when vehicle is unlocked):
If central locking is activated only once (with

key or keyless entry), the driver-side door and
the fuel filler flap are unlocked, while all other
doors and the rear lid remain locked.
If central locking is immediately activated a

second time, the remaining doors and the rear
lid are unlocked.
01-96
Standard coding table for vehicles (tailgate with soft-touch) 1999 :
Vehicle Central locking version Standard

type coding
Audi A4 00001
Vehicles with central locking
00267
Vehicles with central locking and anti-theft warning system
12865
Vehicles with central locking and radio-frequency remote control
13131
Vehicles with central locking, anti-theft warning system and radio-frequency remote
control
Note:
Coding for vehicles which have tailgates equipped with soft-touch, incorporates:
During mechanical unlocking (via tailgate lock), the tailgate unlocks and opens. In this way, the tailgate can be opened without
operating soft-touch.
01-97
Standard coding table for vehicles 18.00 :
Vehicle Central locking version Standard

type coding
Audi A4 02049
Vehicles with central locking
02315
Vehicles with central locking and anti-theft warning system
14913
Vehicles with central locking and radio-frequency remote control
15179
Vehicles with central locking, anti-theft warning system and radio-frequency remote
control
Notes:
Coding for vehicles from cw 18.00 incorporates:
Changed door or window regulator logic. As soon as the door is opened with "terminal. 15 off" the window regulators can
no longer be operated.
During mechanical unlocking (via tailgate lock), the tailgate unlocks and opens. In this way, the tailgate can be opened
without operating soft-touch.
01-98
All vehicles:
Beside the basic coding, it is possible to offer the

customer the following additional functions:
To activate the following additional functions, the

following number value must be added to the
respective basic coding.
+4
Safety central locking (SCL)
+ 32
Automatic locking of the vehicle at
a speed of approx. 15 km/h
(with SCL
+ 36)
The value 4 for SCL and 32 for automatic locking

above a speed must be added to the current
coding.
e.g. CL-pump with ATS/remote and SCL (15179

+ 4 = 15183).
Notes:
Safety central locking (SCL) has the following

function (vehicle locked):
If the CL is only operated once (via key or

remote control), the drivers door and the tank
flap will be unlocked while all other doors and
tailgate remain locked.
If the CL is immediately operated for a second

time, the remaining doors and tailgate will also
be unlocked.
01-99
Read Measuring Value Block (scan tool

function 08)
Note:
The current system condition can be determined

by using "Read Measuring Value Block" function
08.
Carrying out "Read Measuring Value Block"

function 08

Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.

08 - Read Measuring Value Block
Read Measuring Value Block Indicated on display

- Press buttons -0-, -0- and -1- to input display group number 1 (001).
The selected measuring value block is now indicated in standard format.
01-100
Read Measuring Value Block, overview
Display group 001
Read Measuring Value Block 1 Indicated on display

0100 100 0000 0000
X
Rear lid: 1 = opened, 0 = closed
X Luggage compartment light:1 = light on, 0 = light off
X Switch for unlocking rear lid (A8 only):
1 = activated, 0 = not activated
Motor for unlocking rear lid (A8 only):
1 = motor running, 0 = motor not running
X
XX Actuator switch or internal switch at passenger-side door:
00 = not activated, 01 = lock, 10 = unlock, 11 = not permissible
Actuator switch or internal switch at driver-side door:
XX 00 = not activated, 01 = lock, 10 = unlock, 11 = not permissible
X
Passenger-side door and rear doors: 1 = open, 0 = closed (USA: only rear doors)
X Driver-side door: 1 = open, 0 = closed (USA: driver-side and passenger-side doors)
X Hood: 1 = open, 0 = closed
Position of key in lock cylinder
X
Opening driver-side and passenger-side doors: 1 = key activated, 0 = key in middle position
X Closing driver-side and passenger-side doors: 1 = key activated, 0 = key in middle position
X Opening rear lid: 1 = key activated, 0 = key in middle position
X Closing rear lid: 1 = key activated, 0 = key in middle position
01-101
Display group 002

0100 1000 111
X
Terminal 15: 1 = Ignition on, 0 = Ignition off
X S-contact: 1 = S-contact on, 0 = S-contact off
X Ground signal from radio: 0 = Radio installed, 1 = Radio removed
X
Remote transmitter button "open": 1 = activated, 0 = not activated
X Remote transmitter button "close": 1 = activated, 0 = not activated
X Remote transmitter button open "rear lid" (A8 only): 1 = activated, 0 = not activated
X Remote transmitter button "panic" (USA only): 1 = activated, 0 = not activated
X
Interior light controls: 1 = interior light on, 0 = interior light off
X Control wire for window regulator/sunroof:
1 = Terminal 87 (maintaining voltage supply), 0 = Ground
Function "comfort close:" 1 = comfort close activated, 0 = not activated
X
Function "comfort open:" 1 = comfort open activated, 0 = not activated
X
01-102
Display group 003

0 0001 0 0000
X Remote transmitter button "open": 2)
Remote transmitter button "close": 2)
X 1 = activated, 0 = not activated
Remote transmitter button open "rear lid" (N/A): 2)
X Remote transmitter button "Panic" (N/A): 2)
X
X
Disregard measuring value
X
Keyless entry key memory position 4 1): 1 = position occupied, 0 = not occupied
X Keyless entry key memory position 3 1): 1 = position occupied, 0 = not occupied
X
Disregard measuring value
1) When you activate keyless entry, the relevant keyless entry key memory position blinks.
2) This measuring value block also shows non-coded keyless entry keys (e.g. for function control of keyless entry).
01-103
Display group 004 (vehicles up to software version D04)

100 1011 1100 1100
X
Anti-theft system activated: 0 = no, 1 = yes
X Safety central locking: 0 = no, 1 = yes
X Disregard measuring value: coding always 0
X
X
Anti-theft system activated: 0 = no, 1 = yes
X Interior monitoring system is OBD capable: 0 = yes, 1 = no
X Locking vehicle above a speed: 0 = yes, 1 = no
X Vehicle is a convertible: 0 = no, 1 = yes
X
USA-Door logic 1) activated: 0 = no, 1 = yes
X Confirmation of anti-theft system via emergency flashers: 0 = no, 1 = yes
X Confirmation of anti-theft system via horn: 0 = no, 1 = yes
X Confirmation of keyless entry via emergency flashers: 0 = no, 1 = yes
X
Remote transmitter activated: 0 = no, 1 = yes
X
Activation of security central locking also possible with remote transmitter: 0 = no, 1 = yes
X Comfort closing also possible with remote transmitter: 0 = no, 1 = yes
1) Window regulators will not work if ignition is off and driver-side door is open.
01-104
Display group 004 (vehicles from software version D05)
Read measuring value block Indicated on display

4
100 1111 1000 1100
X
Anti-theft warning system activated: 0 = No, 1 = Yes
X Safety-CL activated: 0 = No, 1 = Yes
X Confirmation of anti-theft warning system via emergency flashers:0 = No, 1
= Yes
Tailgate opening, lock cylinder rear: 0 = No, 1 = Yes
X
X
Anti-theft warning system activated: 0 = No, 1 = Yes
X Interior monitoring is OBD cabable: 0 = Yes, 1 = No
X Locking vehicle above a speed: 0 = No, 1 = Yes
X Vehicle is a Cabrio: 0 = No, 1 = Yes
X
USA-door logic 1) activated: 0 = No, 1 = Yes
X Confirmation of radio-frequency remote control button "open" via emergency flashers:
0 = No, 1 = Yes
Confirmation of anti-theft warning system via ATS horn: 0 = No, 1 = Yes
X
Confirmation of radio-frequency remote control button "lock" via emergency flashers:
X 0 = No, 1 = Yes
X
Radio-frequency remote control activated: 0 = No, 1 = Yes
X For safety central locking selection, CL-function for operation via radio frequency remote, otherwise SCL-
function: 0 = No, 1 = Yes
X
Comfort locking/ -unlocking also possible via radio-frequency remote control: 0 = No, 1 = Yes
1) All window regulators are not functional, if the ignition is switched off and the drivers door is open at the same time.
01-105
Remote transmitter, coding
Two remote transmitters are supplied with the

vehicle. If further transmitters are required, they
must be coded to interact properly with the
central locking control module.
This procedure must be performed after

changing the batteries in keys with remote
control function, or if the scan tool displays DTCs
of 00955 to 00958
Remote transmitter coding procedure
- Switch ignition on (using separate key).
- Check how many transmitters have already

been coded in measuring value block 003
Read Measuring Value Block page 01-99 .

0 0001 0 0000
Display field 2 indicates how many remote transmitters have been coded
and in which memory positions (in the example given, 1 transmitter in
position 1).
- Lock vehicle from outside using key to be coded via driver-side door
lock.
- Press "unlock" button within 5 seconds often enough to reach next
memory position (in example given, twice).
Every press of the button is confirmed by the emergency flashers and

the anti-theft system horn.
- Wait 5 seconds.
01-106
- Now press "unlock" button one more time

(vehicle unlocks).
- Switch ignition off and remove ignition key.
- Check function of new transmitter.
- Check display field 2 in measuring value block

003. It should now display another "1" (in
example given: 1100).
Note:
Be sure that new transmitters are always coded

into free memory positions. If occupied positions
(distinguishable by a "1") are used, the
transmitter previously coded to this position will
no longer work.
Existing remote transmitter recoding

procedure
This procedure must be performed after

changing the batteries in keys with remote
control function, or if the scan tool displays DTCs
of 00955 to 00958
- Press any button on transmitter.
If vehicle does not respond by locking or
unlocking:
- Lock and unlock vehicle within 30 seconds using

driver-side lock.
- Now check function of recoded remote

transmitter.
Clearing memory positions
Note:
It is possible to clear all memory positions, e.g. if

a customer loses a remote transmitter. Proceed
as follows:
01-107
- Switch ignition on using key.
- Then mechanically lock central locking from

outside vehicle using key.
- Activate remote transmitter "unlock" button on

key five times at one second intervals. A short
horn signal will sound each time.
- Then, after 6 seconds, press remote transmitter

"unlock" button to confirm this clearing
procedure one more time.
Central locking should no longer unlock itself via

remote transmitter.
- Switch ignition off.
Up to four transmitters can now be coded again.
01-70
Readiness code
Readiness code, checking
Note:
The readiness code will be erased:
When Diagnostic Trouble Code (DTC) memory

is erased
When the Engine Control Module (ECM)

harness connector is disconnected (e.g. to
connect VAG1598/22 test box)
When the battery is disconnected
Required special tools and test equipment
VAG1551 Scan Tool (ST) with VAG1551/3

adapter cable
Checking
- Connect VAG1551/VAG1552 Scan Tool (ST)

and press buttons -0- and -1- to insert "Engine
Electronics" address word 01 (with ignition
switched on) page 01-8 .
Select function XX
function 08, and press -Q- button to confirm input.
01-71
Read Measuring Value Block HELP Indicated on display

- Press buttons -0-, -8- and -6- to input display group number 86 (086),
and press -Q- button to confirm input.
Read Measuring Value Block 86 Indicated on display (1-4 display fields)

1 2 3 4
- Check readiness code values in display field 1.
Specified value: 00000000
Note:
The readiness code is generated as soon as only zeros are shown in

display field 1.
- Press button.

Select function XX
- Press buttons -0- and -6- to select "End Output" function 06, and press
If the readiness code was not generated, generate readiness code again
page 01-73 .
- Check readiness code page 01-70 . If DTC memory has been

erased, or ECM has been disconnected from B+, generate readiness
code again page 01-73 .
01-72
Explanation of 8-digit readiness code
Readiness code is generated only when all display values = 0

1 2 3 4 5 6 7 8 Diagnosis
0 Three Way Catalytic Converter (TWC)
0 TWC heating (not applicable / always "0")
0 EVAP system and fuel tank leak detection test
0 Secondary Air Injection (AIR) system
0 Air conditioning system (diagnosis not applicable / always "0")
0 Oxygen Sensor (O2S) control
0 Oxygen Sensor (O2S) heating
0 Exhaust Gas Recirculation (EGR) system (not applicable / always "0")
01-73
Required special tools and test equipment
VAG1551 Scan Tool (ST) with VAG1551/3

adapter cable
Test requirements
No malfunctions stored in DTC memory
Engine not stopped (ignition not switched off)

during the test
Vehicle not moving
All electrical consumers switched off (coolant

fan must not run during test)
Test sequence
- Connect VAG1551/VAG1552 Scan Tool (ST)

and press buttons -0- and -1- to insert "Engine
Electronics" address word 01 (with ignition
switched on) page 01-8 .
01-74
Step 1: Check DTC memory

Select function XX
- Press buttons -0- and -2- to select "Check DTC Memory" function 02,
No DTC recognized Indicated on display
If one or more DTCs are stored:
- Repair cause of malfunction.

- Erase DTC memory.
- Stop engine, start engine again, and road test.
Safety precautions for road testing vehicle page 24-9
- Check DTC memory again and erase.
If no DTCs were recognized:
- Press button.
01-75
Step 2: Erase DTC memory

Select function XX
- Press buttons -0- and -5- to select "Erase DTC Memory" function 05,
Note:
When erasing DTC memory, the readiness code is also erased.

DTC Memory is erased
- Press button.
01-76
Step 3: Adaptation of throttle valve control

module to ECM

Select function XX


1 2 3 4
- Press -4- button to select "Basic Setting" function 04 (adaptation of
throttle valve control module to ECM)
System in Basic Setting 60 Indicated on display (1-4 display fields)

1 2 3 4
01-77
- Check specified values in display fields 3 and

4:
Display fields
1 2 3 4
Display group 60: Adaptation of throttle valve control module to Engine Control Module (ECM)
Display xxx xxx Idle ADP.runs
Part Throt ADP. OK
Full Throt ADP.ERROR
Decel
Enrich
Indicated Throttle valve angle Throttle drive angle Operating condition Adaptation status
Specified value --- --- Idle ADP. OK
If "ADP. ERROR" is indicated in display field 4:
- Check DTC memory page 01-16 .
If the specified value "ADP. OK" is indicated in

display field 4:
- Press button.
01-78
Step 4:
- Start engine and let run at idle.
Step 5: Oxygen Sensor (O2S) control

operating condition

Select function XX


1 2 3 4
01-79
- Increase engine speed to 1800-2200 RPM.
- Hold at 1800-2200 RPM until specified value

"111" is shown in all of display fields 1 - 4 (
table).
Display fields
1 2 3 4
Display group 30: Oxygen Sensor (O2S) control operating condition, Bank 1 and Bank 2
Display xxx xxx xxx xxx
Indicated Status of Heated Oxygen Status of Heated Oxygen Status of Heated Oxygen Status of Heated Oxygen
Sensor (HO2S), bank 1, Sensor (HO2S) 2, bank 1 Sensor (HO2S), bank 2, Sensor (HO2S) 2, bank 2
sensor 1, before TWC sensor 2, after TWC sensor 1, before TWC sensor 2, after TWC
Specified 111 111 111 111
value
Evaluation page 01-80
If one of the specified values is not indicated:
If the specified values for display fields 1-4 are

not indicated:
- Continue to hold engine speed at 1800-2200

RPM.
01-80
Explanation of 3-digit value in display fields 1

and 2:
When display = 1
1 2 3
1 Oxygen Sensor (O2S) control active
1 Heated Oxygen Sensor (HO2S)
operational
1 Oxygen Sensor (O2S) heater ON
Step 6: Oxygen sensor aging (time period)
- Press button -4- to select "Basic Setting"

function 04.
- Press button -3- four times to advance to display

group number 34.

1 2 3 4
- Hold engine speed at 1800-2200 RPM until display changes from "Test
OFF" to "Test ON" in display field 4.
01-81
- Continue to hold at 1800-2200 RPM until

specified value "B1-S1. OK" is indicated in
display field 4.
Display fields
1 2 3 4
Display group 34: Oxygen sensor aging, Bank 1 (time period of oxygen sensor)
Display xxxx RPM xx.xx ms xx.xx s Test OFF/Test
ON
B1-S1 OK/
B1-S1 n. OK
Indicated Engine speed Engine load Time period of HO2S before TWC, bank 1, Diagnostic status
sensor 1
(increments of 40
RPM) Diagnostic result
Range 0-6800 RPM 0.00-12.75 0.00-5.00 s ---
ms
Specified 1800-2200 RPM 0.80-2.00 ms 0.20-2.10 s B1-S1 OK
value
If "B1-S1 n. OK" is indicated in display field 4:
If the specified value "B1-S1 OK" is indicated in
display field 4:

RPM.
- Press button -3- once to advance to display

group number 35.
01-82

1 2 3 4
- Continue to hold at 1800-2200 RPM until specified value "B2-S1 OK" is
indicated in display field 4.
Display fields
1 2 3 4
Display group 35: Oxygen sensor aging, Bank 2 (time period of
oxygen sensor)
Display xxxx RPM xx.xx xx.xx s Test
ms OFF/Test
ON
B2-S1 OK/
B2-S1 n.
OK
Indicated Engine speed Engine Time period of Diagnostic
(increments of 40 load HO2S before status
RPM) TWC, bank 2,
sensor 1 Diagnostic
result
Range 0-6800 RPM 0.00- 0.00-5.00 s ---
12.75
ms
Specified 1800-2200 RPM 0.80- 0.20-2.10 s B2-S1 OK
value 2.00 ms
If "B1-S1 n. OK" is indicated in display field 4:
If the specified value "B1-S1 OK" is indicated in display field 4:
- Continue to hold engine speed at 1800-2200 RPM.

- Press -C- button.
01-83
Step 7: Three Way Catalytic Converter (TWC)

diagnosis
Basic Setting HELP Indicated on display


1 2 3 4
- Continue to hold at 1800-2200 RPM until specified value "Cat B1 OK"
is indicated in display field 4.
Note:
The test time for TWC diagnosis is approx. 60 seconds.
01-84
Display fields
1 2 3 4
Display group 46: Three Way Catalytic Converter (TWC), Bank 1 diagnosis
Display x.xx x xx.x s Test OFF/Test ON
Cat B1 OK/
Cat B1 n. OK
Indicated Amplitude ratio Exceeded diagnosis range Test time of TWC diagnosis Diagnostic status
Diagnostic result
Range 0.00-1.00 0-9 00.0-60.0 ---
Specified value 0.00-0.26 0-2 60.0 s Cat B1 OK
If "Cat B1 n. OK" is indicated in display field 4:
If specified value "Cat B1 OK" is indicated in

display field 4:

RPM.
- Press button -3- once to advance to display

group number 47.

1 2 3 4
01-85
- Hold engine speed at 1800-2200 RPM until

display changes from "Test OFF" to "Test ON" in
display field 4.
- Continue to hold at 1800-2200 RPM until

specified value "Cat B2 OK" is indicated in
display field 4.
Note:
The test time for TWC diagnosis is approx. 60

seconds.
Display fields
1 2 3 4
Display group 47: Three Way Catalytic Converter (TWC), Bank 2 diagnosis
Display x.xx x xx.x s Test OFF/Test ON
Cat B2 OK/
Cat B2 n. OK
Indicated Amplitude ratio Exceeded diagnosis range Test time of TWC diagnosis Diagnostic status
Diagnostic result
Range 0.00-1.00 0-9 00.0-60.0 ---
Specified value 0.00-0.26 0-2 60.0 s Cat B2 OK
If "Cat B2 n. OK" is indicated in display field 4:
If specified value "Cat B2 OK" is indicated in

display field 4:
- Press -C- button.
01-86
Step 8: Evaporative Emissions (EVAP)

system and fuel tank leak detection
Note:
During this diagnosis there should be no engine

load, otherwise the diagnosis is interrupted and
can only be restarted after pressing the
accelerator pedal momentarily.
Basic Setting HELP Indicated on display


1 2 3 4
If the diagnosis is initiated by the ECM, the display changes from "Test
- Let engine continue to run at idle until the specified value "EVAP OK" is
Note:
If the display changes from "Test ON" to "Test OFF" during the diagnosis,
briefly accelerate the engine to reset and repeat the test.
01-87
Display fields
1 2 3 4
Display group 70: Evaporative Emissions (EVAP) canister purge regulator valve diagnosis
Display xxx % xx.x % xx.xx g/s Test
OFF/Test ON
EVAP OK/
EVAP n. OK
Indicated Opening of EVAP canister purge Oxygen sensor control Idle Air Control (IAC) valve Diagnostic
regulator valve during diagnosis deviation during diagnosis deviation during diagnosis status
Diagnostic
result
Range 0 - 100 % -25.0 to +25.0 % -2.78 to +2.85 g/s ---
Specified 0 - 93 % -15.0 to +15.0 % -1.00 to 0.00 g/s EVAP OK
value
If "EVAP n. OK" is indicated in display field 4:
If the specified value "EVAP OK" is indicated in

display field 4:
- Press -3- button to input display group number

71.
01-88
Initiate basic setting 71 Indicated on display (1-4 display fields)

1 2 3 4
- Let engine continue to run at idle until the specified value "Syst. OK" is
Display fields
1 2 3 4
Display group 71: Fuel tank leak detection
Display Reed op. Small leak/large leak Syst.Test Test OFF/Test ON
Reed cl. disconnection Check Syst. OK/
Check end Syst. n.OK

Indicated Status: Reed contact Error message System status Diagnostic status
Diagnostic result
Range --- --- --- ---
Specified value Reed op. --- Check end Syst. OK
01-89
Notes:
If display field 4 changes from "Test ON" to "Test

OFF" and "Abort" appears in display field 2,
repeat the diagnosis of fuel tank leak detection.
Shut the engine off, start the engine again and
repeat the leak detection test.
Diagnosis conditions for fuel tank leak detection:
Intake Air Temperature (IAT) must be less than

60 C (140 F) display group 4, display field 4
(the temperature can be reduced by opening
the hood).
The throttle valve angle for vehicles with

automatic transmissions must be smaller than
10 display group 3, display field 3
The throttle valve angle for vehicles with

manual transmissions must be smaller than
10 display group 3, display field 3
If "Syst. n. OK" is indicated in display field 4:
If the specified value "Syst. OK" is indicated in

display field 4:
- Press button.
01-90
Step 9: Secondary Air Injection (AIR) system

diagnosis
Initiate basic setting HELP Indicated on display


1 2 3 4
- Let engine continue to run at idle until the specified value "Syst. OK" is
01-91
Display fields
1 2 3 4
Display group 77: Secondary air injection system diagnosis
Display xx.x % xx. x % xx.x C Test OFF/Test
ON
Syst. OK/
Syst. n.OK
Indicated O2S control deviation during O2S control deviation during Coolant Diagnostic
diagnostics diagnostics temperature status
Bank 1 Bank 2 Diagnostic

result
Range --- --- -46.5 to +141.5 ---
C
Specified --- --- greater than 70.0 Syst. OK
value C
If "Syst. n. OK" is indicated in display field 4:
If the specified value "Syst. OK" is indicated in

display field 4:
- Press button.
Step 10: Check readiness code
- Check readiness code page 01-70 .
01-71
Code Control Module

(function 07)
If control module does not indicate coding
corresponding to vehicle, or if control module has
been replaced, code it as follows.
Procedure

Display on VAS5051:
- Select diagnostic function "07 - Code control module" in selection -1-.
Display on VAS5051:
1 - Enter code Max. input value = 32767

- Enter control module coding in button field -2- according to coding table
Page 01-73 .
01-72
XX Country/Exhaust
X Transmission
X Vehicle model
Coding example
16501 USA ULEV 1) (emissions regulations),
Front Wheel Drive (FWD) with ESP 2) , 5
speed automatic transmission, Audi A4
1)ULEV: Abbreviation for Ultra Low Emission

Vehicle
2)ASR/ESP: Abbreviation for Anti-Slip

Regulation/Electronic Stability Program
Display on VAS5051:
1 - Coding will be performed

- Wait until the next indication appears on display.
01-73
Coding table
Country/Exhaust 16 USA ULEV (emissions regulation)

Drive/Additional Functions 0 Front wheel drive with ABS
2 All wheel drive with ABS
5 Front Wheel Drive (FWD) with ASR/ESP:
Transmission 0 5 speed manual transmission
01-71
Code Control Module

(function 07)
If control module does not indicate coding
corresponding to vehicle, or if control module has
been replaced, code it as follows.

9.

Select function XX
- Press buttons -0- and -7- to select "Code control module" and press -
Q- button to confirm input.
Code Control Module Q When indicated on display:

- Input control module coding according to code table Page 01-73 .
XX Country/Exhaust
X Transmission
X Vehicle model
01-72
Coding example
07251 USA LEV 1) (emissions regulations), All
Wheel Drive (AWD) without ESP 2) , 5
speed Automatic transmission, Audi A4
1) LEV: Abbreviation for Low Emission Vehicle
2)ESP: Abbreviation for Electronic Stability

Program
3B0907551BA 2.8l V6/5V G 0003 VAG1551 Scan Tool (ST) display indicates control module identification,
e.g.:
Note:
Function is unknown or When indicated on display:

cannot be carried out at the moment
An unauthorized code number was entered.
- Press button.

Select function XX
01-73
Coding table
Country/Exhaust 07 USA LEV (emissions regulation); Characteristic: Vehicles with Leak

Detection Pump (LDP)
Drive/Additional 2 All Wheel Drive (AWD) without Electronic Stability Program (ESP)
Functions
5 Front Wheel Drive (FWD) with Anti-Slip Regulation (ASR)
Transmission 0 5 speed manual transmission
Notes:
Electronic Stability Program is abbreviated as "ESP". Check the ESP switch in the center console to determine whether
the vehicle is equipped with ESP.
Anti-Slip Regulation is abbreviated as "ASR".
The abbreviation "LEV" stands for Low Emission Vehicle.
01-74

(function 08)
Test requirements:

A/C switched off.
Test sequence

or, depending on desired operation:
- Start engine.
Display on VAS5051:
- Select diagnostic function "08 - read measured value block" in

selection -1-.
01-75
Display on VAS5051:

- Enter desired 3-digit display group number in button field -2- and press
Note:
Which display group should be chosen depends on current function and

component tests.
Indicated on VAS5051 for display group 000:
1 - Display group 0
2 - Display field 1 2 3 4 5 6 7 8 9 10
01-76
Indicated on VAS5051 for display group 001 to 255:
1 - Display group X
2 - Display field 1
Display field 2
Display field 3
Display field 4
Notes:
If no display follows, a display field is not assigned.
Display group VAS5051 tester

higher Press button.
Lower Press button.
- Press "08 - erase DTC memory" to end function button.
01-74

(function 08)
Test requirements:

A/C switched off.
Steering in "straight-ahead" position
Test sequence

9.

Select function XX
Read Measuring Value Block Q When indicated on display:

- Enter desired three digit display group number and confirm by pressing
the -Q- button.
01-75
Note:
Which display group should be chosen depends

on current function and component tests.
Read Measuring Value Block 0 Indicated on display for display group 000:
1 2 3 4 5 6 7 8 9 10
Read Measuring Value Block 1 Indicated on display (example) for display group 001:
1 2 3 4
Notes:
Display can be printed out on the paper roll when printer is switched
on.
Display group VAG1551 Scan Tool (ST) VAS5051 tester

higher Press button -3- Press s button.
Lower Press button -1- Press t button.
01-76
Readiness code
During a test sequence (which must be carried

out in its entirity), On Board Diagnostic (OBD)
checks the function of each of these systems and
then changes the character assigned to it in the
8-digit display from a "1" to a "0".

display field 1).

01-77
Readiness code is returned to "0 1 1 0 1 1 0

1" if:

installed
In this case, readiness code must be re-

Note:

by the control module within a "short trip" and
readiness code is generated on its own. In this
case, however, concluding control possibilities
are not available, meaning that it will not be
indicated whether all positions of the readiness
code are set to "0".
01-78
Test sequence

9.

Select function XX
Read Measuring Value Block Q When indicated on display:

Read Measuring Value Block 86 When indicated on display:

1 2 3 4
- Check readiness code in display field 1
01-79
Display fields
1 2 3 4
Display 00000000 XXXXXXXX XXXXXXXX XXXXXXXX
Indicated Status-digits individual tests carried individual tests carried individual tests carried
out out out
completed tests
Functional 1 = not 1 = not completed 1 = not completed 1 = not completed
range completed
0 = completed
Specified value 00000000 XXXXXXXX XXXXXXXX XXXXXXXX
Notes Meaning of readiness code Page 01-80
time DTC memory was erased or a new control module was implemented. After DTC memory is erased, all testable values
are set to 1, after the test is performed, the values are set to 0.
01-80


Indication always 0
EVAP system

Secondary Air Injection system

Indication always 0
Oxygen sensors

Indication always 0
Note:
Readiness code is not generated until all indications in display field 1 show "0"
01-81

- Press button.

Select function XX
- Check DTC memory as a control measure Page 01-15 (no
malfunctions may be stored).
01-82
Requirements
test).
A/C system switched on.
Coolant temperature at least 80 C Display group 4, display field

3. Important: Drive engine warm via road test if possible.
Note:
01-83
Test requirement
Ignition switched on.

9.

Select function XX
- Press buttons -0- and -2- to select "Check DTC memory" and press -Q-
X DTC recognized Number of stored DTCs or "No DTC recognized" will be indicated on
display.
If a DTC is stored:
- Repair malfunction, erase DTC memory. Road test vehicle and then
check DTC memory as a control measure.
- Press button.
01-84
Test requirement

Select function XX
- Press buttons -0- and -5- to select "Erase DTC memory" and press -Q-
Note:
be re-generated.
Rapid data transfer When indicated on display:

DTC Memory is erased
- Press button.
01-85

Test requirement

Select function XX
Basic Setting Q When indicated on display:

System in Basic Setting 60 When indicated on display:

1 2 3 4
- Check specified value in display field 4.
01-86
Display fields
1 2 3 4
(angle (angle
sensor 1) sensor 2)
Functional 0 to 100 % 0 to 100 % 0 to 8 ADP in progress
range
ADP OK
ADP ERROR
value
Notes After adaptation, the adaptation step If "ADP ERROR." is displayed:

obtained: Note, page
Page 24-147 .
- Press -C- button.
01-87
Work step 4: Kick down function, adapting
Test requirement
Initiate basic setting Q When indicated on display:


1 2 3 4
Note:
There will be a prompt: "Activate kick-down"
down.
Note:
During adaptation of the kick down point, the VAG1551 will display "Kick
down ADP in progress". After successful adaptation of the kick down
point, the VAG1551 will display "Kick down ADP OK".
01-88
Display fields
1 2 3 4
down
Indicated Sensor 1 for Sensor 2 for Kick Adaptation condition
down
Pedal Pedal
position position
Functional 0 to 100 % 0 to 50 % Kick operate
range down
ADP in progress
ADP OK
ADP ERROR
Specified value 12 to 97 % 4 to 49 % Kick ADP OK
down
Notes If "ADP ERROR." is displayed: Check DTC memory
Page 01-15 .
tester or if the accelerator pedal is released while adaptation is running despite the fact that adaptation is not yet complete.
In both cases, "Basic Setting" must be exited and the adaptation must be performed again.
- Press -C- button.
01-89


Note:
After starting engine, it may be necessary to

select the Engine Control Module (ECM) again
using "address word" 01 and the function "Initiate
basic setting" using "04".
- Install VAG1788/10 RPM adjuster on the

accelerator pedal and raise the engine speed.
Specification: 2200 RPM


1 2 3 4
- Check oxygen sensor status in display fields 1 to 4.
Note:
01-90
Display fields
1 2 3 4
Display group 030: Oxygen sensor status with engine at idle
Display XXX XXX XXX XXX
Indicated Oxygen sensor status, Oxygen sensor status, Oxygen sensor status, Oxygen sensor status,
bank 1, sensor 1 bank 2, sensor 1 bank 2, sensor 1 bank 2, sensor 2
Functional 0 = off 0 = off 0 = off 0 = off
range
1 = on 1 = on 1 = on 1 = on
Specified 111 110 111 110
value
X X X Display fields 1 to 4
X Oxygen sensor control
0= not active
1 = active
X Operational readiness of oxygen sensor
0= not active
1 = active
X Condition of oxygen sensor heating
0= not active
1 = active
01-91

Test requirement


1 2 3 4
- Check specified value in display field 4 after indication "Test ON"
appears:
Note:
01-92
Display fields
1 2 3 4
Indicated Engine speed Exhaust Period duration Diagnostic condition
(RPM) temperature Oxygen sensor
before
Catalytic
converter
Functional 630 to 6800 70 to 850 C 0 to 3.0 s Test OFF
range RPM
Test ON
B1-S2 OK
B1-S2 not OK
Specified 2200 RPM above 380 C 0.1 to 1.8 s B1-S2 OK
value
Notes If "B1-S1 not OK" is displayed: Check Diagnostic
Trouble Code (DTC) memory Page 01-15
- Press -C- button.

- Press buttons -0-, -3- and -5- to select "display group number 035"
01-93

1 2 3 4
Display fields
1 2 3 4
Indicated Engine speed Exhaust Period duration Diagnostic condition
(RPM) temperature Oxygen sensor
before
Catalytic
converter
Functional 630 to 6800 70 to 850 C 0 to 3.0 s Test OFF
range RPM
Test ON
B2-S2 OK
B2-S2 not OK
Specified 2200 RPM above 380 C 0.1 to 1.8 s B2-S2 OK
value
Notes If "B2-S1 not OK" is displayed: Check Diagnostic
- Press -C- button.
01-94

readiness of oxygen sensors behind catalytic
converter
Test requirement


1 2 3 4
- Check specified values in display fields 2 and 4.
01-95
Display fields
1 2 3 4
Display group 036: Operational readiness of the oxygen sensor behind catalytic converter (bank 1 and bank 2)
Display x.xxx V --- x.xxx V ---
Indicated Voltage of oxygen Diagnostic condition Voltage of oxygen Diagnostic condition
sensors behind sensors behind
catalytic converter, catalytic converter,
bank 1 bank 2
Functional 0.100 to 1.000 V Test OFF 0.100 to 1.000 V Test OFF
range
Test ON Test ON
B1-S2 OK B2-S2 OK
B1-S2 not OK B2-S2 not OK

Specified smaller than 0.4 V B1-S2 OK smaller than 0.4 V B2-S2 OK
value or or
larger than 0.5 V larger than 0.5 V

Notes If "B1-S2 not OK" is If "B2-S2 not OK" is
displayed: Check Diagnostic displayed: Check Diagnostic
Trouble Code (DTC) memory Trouble Code (DTC) memory
Page 01-15 Page 01-15
- Press -C- button.
01-96

control system
Test requirement


1 2 3 4
01-97
Display fields
1 2 3 4
Indicated Load Voltage of oxygen sensors Oxygen sensor Diagnostic condition
behind catalytic converter, correction value
bank 1 between sensor 1
and sensor 2 (bank
1)
Functional 12 to 0.100 to 1.000 V -800 to 800 ms Test OFF
range 100 %
Test ON
System OK
System not OK
Specified 12 to 26 0.100 to 1.000 V -800 to 800 ms System OK
value %
Notes If "System not OK" is displayed: Check
Diagnostic Trouble Code (DTC) memory
Page 01-15
- Press -C- button.

- Press buttons -0-, -3- and -8- to select "display group number 038"
01-98

1 2 3 4
Display fields
1 2 3 4
Indicated Load Voltage of oxygen sensors Oxygen sensor Diagnostic condition
behind catalytic converter, correction value
bank 2 between sensor 2
and sensor 2 (bank
1)
Functional 12 to 0.100 to 1.000 V -800 to 800 ms Test OFF
range 100 %
Test ON
System OK
System not OK
Specified 12 to 26 0.100 to 1.000 V -800 to 800 ms System OK
value %
Notes If "System not OK" is displayed: Check
Page 01-15
- Press -C- button.
01-99

aging behind catalytic converter
Test requirement


1 2 3 4
01-100
Display fields
1 2 3 4
Display group 043: Oxygen sensor aging diagnostic, oxygen sensor behind catalytic converter (bank 1)
Indicated Engine speed Exhaust Voltage of oxygen sensors Diagnostic condition
(RPM) temperature behind catalytic converter,
bank 1
Functional 630 to 6800 70 to 850 C 0.100 to 1.000 V Test OFF
range RPM
Test ON
B1-S2 OK
B1-S2 not OK
Specified 2200 RPM above 380 C 0.100 to 1.000 V B1-S2 OK
value
Notes If "B1-S2 not OK" is displayed: Check
Page 01-15
- Press -C- button.

-
Press buttons -0-, -4- and -4- to select "display group number 044"
01-101

1 2 3 4
Display fields
1 2 3 4
Indicated Engine speed Exhaust Voltage of oxygen sensors Diagnostic condition
(RPM) temperature behind catalytic converter,
bank 2
Functional 630 to 6800 70 to 850 C 0.100 to 1.000 V Test OFF
range RPM
Test ON
B2-S2 OK
B2-S2 not OK
Specified 2200 RPM above 380 C 0.100 to 1.000 V B2-S2 OK
value
Notes If "B2-S2 not OK" is displayed: Check
Page 01-15
- Press -C- button.
01-102
Work step 10: Diagnostic of catalytic

converter
Test requirement


1 2 3 4
Note:
01-103
Display fields
1 2 3 4
Indicated Engine Exhaust Catalytic Diagnostic condition
speed temperature converter -
(RPM) conversion
Functional 630 to 6800 70 to 850 C 0.00 to 0.99 Test OFF
range RPM
Test ON
Cat B1 OK
Cat B1 not OK
Specified 2200 RPM above 420 C 0.00 to 0.52 Cat B1 OK
value 1)
0.00 to 0.47
2)
Notes If "Cat B1 not OK" is displayed: Check Diagnostic

Trouble Code (DTC) memory Page 01-15 . If no DTCs
are stored, replace catalytic converter.
1) Manual transmission
2) Automatic transmission
01-104
- Press -C- button.


1 2 3 4
01-105
Display fields
1 2 3 4
Indicated Engine Exhaust Catalytic Diagnostic condition
speed temperature converter -
(RPM) conversion
Functional 630 to 6800 70 to 850 C 0.00 to 0.99 Test OFF
range RPM
Test ON
Cat B2 OK
Cat B2 not OK
Specified 2200 RPM above 420 C 0.00 to 0.52 Cat B2 OK
value 1)
0.00 to 0.47
2)
Notes If "Cat B2 not OK" is displayed: Check Diagnostic

Trouble Code (DTC) memory Page 01-15 . If no DTCs
are stored, replace catalytic converter.
1) Manual transmission
2) Automatic transmission
- Press -C- button.
01-106

valve
- Remove the VAG1788/10 RPM adjuster and

leave engine running at idle.


1 2 3 4
Note:

01-107
Display fields
1 2 3 4
Display xx % xx.x % g/s ---
Indicated Degree tank Oxygen Deviation Diagnostic condition
ventilation valve is sensor of
opened control Idle
deviation control
Functional 0 to 99 % -25.0 to 25.0 Test OFF
range %
Test ON
TVV OK
TVV not OK
Aborted
Specified 0 to 99 % -7.0 to 7.0 x.xx g/s TVV OK
value % 1)
Notes If "TVV not OK" is displayed: Check Diagnostic Trouble

Code (DTC) memory Page 01-15 . Check Evaporative
Emission (EVAP) canister purge regulator valve -N80-
Page 24-128
1)An indication is only displayed if diagnostic result falls within a specified range due to deviation of idle control and not due to
deviation of an oxygen sensor (e.g. sensor 1 from EVAP canister). Otherwise, display field 3 remains empty.
- Press button.
01-108
Work step 12: Diagnostic of tank seal
Test requirements
Intake Air Temperature (IAT) less than 95

C display group 004, display field 4.
Coolant temperature at least 80 C

Display group 4, display field 3
Fuel filler cap opened briefly (to reduce

pressure).


1 2 3 4
Notes:
Test lasts approx. 90 seconds.
When the diagnostic of tank seal is performed several times in a row,
the fuel filler cap must be opened briefly before each test to release
pressure.
01-109
- Check specified value in display field 4 after

indication "Test ON" appears:
Display fields
1 2 3 4
Display group 071: Diagnostic of tank seal
Display --- --- --- ---
Indicated Condition Reed- DTC System Diagnostic condition
Terminal message condition
Functional Reed open Small leak System test Test OFF
range
Reed closed Large leak Measurement Test ON
System not END System OK

OK Measurement
System not OK
Aborted
Aborted
Specified Reed open --- END System OK
value Measurement
Notes If "System not OK" is displayed: Check Diagnostic
- Press -C- button.
01-110

Test requirement
Note:
During diagnostic of the Secondary Air Injection

(AIR) system, the Secondary Air Injection (AIR)
pump will run for several seconds.


1 2 3 4
- Check specified value in display field 4 after indication "Test ON"
appears:
Note:
Secondary Air Injection (AIR) system test lasts approx. 60 seconds.
01-111
Display fields
1 2 3 4
Display group 077: Secondary Air Injection (AIR) system diagnostic
Display xxxx/min xx.x % ---
g/s
Indicated Engine speed Air Relative air Diagnostic condition
(RPM) mass mass
Secondary air
system
Functional 670 to 6800 Test OFF
range RPM
Test ON
System OK
System not OK
Specified 720 to 820 0 to 5 -80 to 20 System OK
value RPM 1)
630 to 730
RPM 2)
Notes If "System not OK" is displayed: Check Diagnostic
1) Front Wheel Drive Vehicles
2) All-Wheel Drive Vehicles
- Press button.

Select function XX
01-112
Work step 14: Readiness code, reading
01-77
Readiness code
During a test sequence which must be performed

completely, On Board Diagnostic (OBD) checks
the function of each of these systems and then
changes the character assigned to it in the 8-digit
indication from "1" to "0" once test has been
performed successfully.

display field 1).

01-78
Readiness code is returned to "0 1 1 0 1 1 0

1" if:
Voltage supply to ECM was cut off (e.g.

connector disconnected, battery disconnected)

installed
In this case, readiness code must be re-

Note:

by the control module and the readiness code is
generated on its own. In this case, however, the
concluding control possibilities are not available,
meaning that it will not be indicated whether the
vehicle is free of malfunctions upon transfer to
the customer.
01-79
Test sequence

Display on VAS5051:
- Select diagnostic function "08 - read measured value block" in

selection -1-.
Display on VAS5051:

- Select function "086" in button field -2- for "Display group number 086"
and press Q button to confirm input.
01-80
Display on VAS5051:
- Check readiness code in display field -1-.

01-81
Display fields
1 2 3 4
Display 00000000 XXXXXXXX XXXXXXXX
Indicated Ready-Bits individual tests carried out individual tests carried out
completed tests
Functional range 1 = not completed 1 = not completed 1 = not completed

Specified value 00000000 XXXXXXXX XXXXXXXX
Note Significance of readiness code Page 01-82
time DTC memory was erased or a new control module was implemented. Once DTC memory is erased, all testable values
are set to "1", after the test is performed successfully, the values are set to "0".
01-82


Indication always 0
EVAP system

Secondary air system

Indication always 0
Oxygen sensors

Indication always 0
Note:
Readiness code is not generated until all indications in display field 1 display "0"
01-83

- Click on - button
- Check DTC memory as a control measure

Page 01-12 (there must not be any DTCs
stored)
01-84
Requirements
Vehicle stationary

test).
A/C switched off.
Coolant temperature at least 80 C Display group 004, display

field 3. Important: Drive engine warm via road test if possible.
Important note:
01-85
Test requirement:

Display on VAS5051:
- In selection -1-, click on the diagnostic function "02 - Check DTC

memory".
Display on VAS5051:
1 - DTC memory content:

0 malfunctions recognized
or
X malfunctions recognized
2 - Malfunction
DTC
malfunction location
malfunction type
01-86
If a DTC is stored:
- Repair malfunction, erase DTC memory. Road

test vehicle and then check DTC memory as a
control measure.
- Click on - button
01-87
Test requirement:
Display on VAS5051:
- In selection -1-, click on the diagnostic function "05 - Check DTC

memory".
Note:
be re-generated.
Display on VAS5051:
1- no indication (before erasing)

or
DTC memory erased
2 - Note:Perform the function?Note: Data is being erased !
- Press on "OK" button in display -2-.
- Click on - button
01-88

Test requirement:
Display on VAS5051:
- In selection -1-, click on the diagnostic function "04 - Basic setting".
Display on VAS5051:

- Select function "060" in button field -2- for "display group number 060"
01-89
Display on VAS5051:
- Check specified values in display fields -3- and -4-.
01-90
Display fields
1 2 3 4
(angle (angle
sensor 1) sensor 2)
Functional 0 to 8 ADP in progress
range
ADP OK
ERROR
value
Note After adaptation, the adaptation step If "ERROR." is displayed:

obtained: Note, Page 24-
130
- Perform next work step.
01-91
Work step 4: Kick down function, adapting1)
1) Only vehicles with automatic transmission
Test requirement:
Display on VAS5051:
- Press button 3 times to change into display group 063.
Note:
There will be a prompt: "Operate kick down".
down.
Note:
During adaptation of the kick down point, "Kick down ADP in progress" will
be indicated in display. After successful adaptation of the kick down point,
"Kick down ADP OK" will be indicated on display.
- Check specified value in display field -4-.
01-92
Display fields
1 2 3 4
down
Indicated Sensor 1 learned kick down value for Throttle Kick Adaptation condition
for Position (TP) sensor down
Pedal
position
Functional Kick operate
range down
ADP in progress
ADP OK
ERROR
Specified 79 to 94 % 79 to 94 % Kick ADP OK
value down
Note If "ERROR." is displayed: Check DTC
memory Page 01-12 .
tester or if the accelerator pedal is released while adaptation is running despite the fact that adaptation is not yet complete. In
both cases, "Basic Setting" must be exited and the adaptation must be performed again.
01-93


Note:
If necessary, vehicle system "01 - engine

electronics" and diagnostic function "04 -basic
setting" must be selected again after engine
start.
- Install VAG1788/10 RPM adjuster on the

accelerator pedal and raise the engine speed to
2600 RPM.
Test requirement:
Engine running at 2600 RPM.
Display on VAS5051:
- Click on - button
01-94
Display on VAS5051:

Display on VAS5051:
- Check oxygen sensor status in display fields -1- and -2-.
Note:
01-95
Display fields
1 2 3 4
Display group 030: Oxygen sensor status
Display XXX XXX
Indicated Oxygen sensor status, bank 1, sensor 1 Oxygen sensor status, bank 2, sensor 1
Functional range 0 = off 0 = off
1 = on 1 = on
Specified value 111 110

X X X Display fields 1 and 2
X Oxygen sensor control: 0= not active; 1 = active
X Operational readiness of oxygen sensor: 0= not active; 1 = active
X Condition of oxygen sensor heater: 0= not active; 1 = active
Notes:
The first position of the 3 digit indication (heating) fluctuates between 0 and 1 at certain operation points.
Oxygen sensor control of oxygen sensor behind catalytic converter (bank 1, sensor 2) is not active without engine load,
meaning that the third position of the 3-digit display is 0.
- Do not start test until indication in display field 1
has reached "111" at least once and indication in

display field 2 has reached "110" at least once.
01-96

Test requirement:
Display on VAS5051:

Note:
01-97
Display fields
1 2 3 4
Display xxxx/min xxx C x.x ---
Indicated Engine speed Exhaust Dynamic Diagnostic condition
(RPM) temperature factor
Functional Test OFF
range
Test ON
B1-S2 OK
B1-S2 not OK
Specified 2600 RPM larger than 350 0.5 to 2.5 B1-S2 OK
value C
Note If "B1-S1 not OK" is displayed: Check DTC
memory Page 01-12 .
01-98

readiness of oxygen sensor behind catalytic
converter
Test requirement:
Display on VAS5051:

01-99
Display fields
1 2 3 4
Display group 036: Operational readiness of oxygen sensor behind catalytic converter (bank 1)
Display x.xxx V ---
Indicated Oxygen sensor voltage Bank 2, Diagnostic condition
sensor 1
Functional Test OFF
range
Test ON
B1-S2 OK
B1-S2 not OK
Specified value 0.100 to 0.950 volts B1-S2 OK
Note If "B1-S2 not OK" is displayed: Check DTC memory
Page 01-12
01-100

control system
Test requirement:
Display on VAS5051:
- Press button to change into display group 037.

01-101
Display fields
1 2 3 4
Display xxx % x.xxx V x.xx ---
Indicated Load Oxygen sensor Oxygen sensor correction value Diagnostic condition
voltage Bank 2, between bank 1, sensor 1 and bank 1,
sensor 1 sensor 2
Functional Test OFF
range
Test ON
System OK
System not OK
Specified 13 to 0.100 to 0.950 volts smaller than 0.02 System OK
value 40 %
Check DTC memory Page 01-
12
01-102

aging behind catalytic converter
Test requirement:
Display on VAS5051:
- Click on - button
Display on VAS5051:

01-103
Display on VAS5051:
01-104
Display fields
1 2 3 4
Display xxxx/min xxx C x.xxx V ---
Indicated Engine speed Exhaust Oxygen sensor voltage Diagnostic condition
(RPM) temperature Bank 2, sensor 1
Functional Test OFF
range
Test ON
B1-S2 OK
B1-S2 not OK
Specified 2600 RPM larger than 350 0.100 to 0.950 volts B1-S2 OK
value C
Note If "B1-S2 not OK" is displayed: Check
DTC memory Page 01-12
01-105
Work step 10: Diagnostic of catalytic

converter
Test requirement:
Display on VAS5051:

- Check specified values in display fields -2- and -4-.
Note:
01-106
Display fields
1 2 3 4
Display xxxx/min xxx C x.xx ---
Indicated Engine Exhaust temperature Measurement Diagnostic condition
speed
(RPM) Catalytic
converter -
conversion
Functional 0 to 8 Test OFF
range
Test ON
Cat B1 OK
Cat B1 not OK
Specified 2600 RPM 550 to 700 C Larger than 1.0 Cat B1 OK
value
Note As long as the exhaust temperature If "Cat B1 not OK" is displayed:
is not within the specified range, the Check DTC memory Page 01-
test will not be initiated. If necessary, 12 . If no DTCs are stored,
increase or decrease RPM replace catalytic converter.
01-107

valve
- Remove the VAG1788/10 RPM adjuster and

leave engine running at idle.
Test requirement:
Display on VAS5051:
- Click on - button
Display on VAS5051:

01-108
Display on VAS5051:
Note:

01-109
Display fields
1 2 3 4
Display xx % xx % ---
Indicated Degree tank Oxygen Diagnostic condition
ventilation valve is sensor control
opened
Diagnostic
value
Functional Test OFF
range
Test ON
TVV OK
TVV not OK
Aborted
Specified 0 to 99 % less than -7 % TVV OK
value
or greater than
7%
Note If "TVV not OK" is displayed: Check DTC memory Page 01-
12 . Check Evaporative Emission (EVAP) canister purge
regulator valve -N80- Page 24-114
01-110

Test requirement:
Display on VAS5051:
- Click on - button
Display on VAS5051:

01-111
Display on VAS5051:
- Depress gas pedal completely (swiftly) and then release it (brief

acceleration of at least 2500 RPM).
Note:
Secondary Air Injection (AIR) system test lasts approx. 60 seconds.
01-112
Display fields
1 2 3 4
Display group 077: Secondary Air Injection (AIR) system diagnostic (Bank 1)
Display xxxx/min xx.x xx % ---
g/s
Indicated Engine speed Air Relative air mass bank 1, Diagnostic condition
(RPM) mass Secondary Air Injection (AIR)
system
Functional Test OFF
range
Test ON
System OK
System not OK
Aborted
Specified FWD: 740 to 2 to 5 more than -20 % System OK
value 860 RPM g/s
AWD: 760 to
880 RPM
Check DTC memory Page 01-12
- Click on - button
Work step 13: Read readiness code
Instrument cluster with long service life, On Board Diagnostic (OBD) (from m.y. 2000) Page 1 of 99
01-79
Instrument cluster with long

service life, On Board
Diagnostic (OBD) (from m.y.
2000)
General information
Technical features of the instrument cluster
The instrument cluster is equipped with a service

display which can process flexible data, that is,
the instrument cluster evaluates various vehicle
based service requirements on input quantities
such as driveability or oil consumption.
The long service life is capable of reproducing

the functions of the standard SRI, when the limits
are set correctly. The limits are variable (in U.S.
with set limits Table Page 01-80 ).
It is also possible to evaluate the oil temperature

sensor. Adaptation channels in the VAG On
Board Diagnostic (OBD) make this possible.
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.EE01.01.2 11/20/2002
01-80
In countries where the standard Service

Reminder Indicator (SRI) values are still used,
such as the USA, the following constant
adaptation values must be entered:
Table for Service Reminder Indicator values

without long service life
Channel 42 (minimum mileage 8000

performance) miles
Channel 43 (maximum mileage 8000
performance) miles
Channel 44 (maximum time interval 365
until next service) days
Channel 45 (oil quality) 1
01-81
The Audi A4 instrument cluster is offered with a

Midline version with Minicheck system and the
Highline version with Driver Information System
(DIS).
The instrument cluster in the Audi S4 is only

offered with the Highline version with Driver
Information System.
The speedometer contains an LCD display for

the odometer and trip odometer.
A LCD display for LCD-clock/date is located in

the tachometer.
The service reminder indicator is displayed in the

center display.
The warning/ indicator lights are integrated in the

speedometer and tachometer.
01-82
Details about the instrument cluster
Operating instructions Audi A4 or Audi S4
The instrument cluster is controlled by a

microprocessor and has extensive On Board
Diagnostic (OBD) capabilities. If malfunctions
occur in any of the system components,
corresponding Diagnostic Trouble Codes (DTC)
are stored in the DTC memory of the instrument
cluster. These can then be identified using the
VAG1551 or VAG1552 Scan Tool (ST).
Note:
The description in this repair manual only refers

to the VAG1551 Scan Tool (ST).
01-83
Malfunction message "dEF" on trip odometer

display
If the control module in the instrument cluster

detects a malfunction in its permanent memory,
the letters "dEF" will appear on the trip odometer
display.
- If "dEF" is indicated on display, replace

instrument cluster Page 90-27 .
Notes for replacing instrument cluster
Do not disassemble instrument cluster.
If necessary, instrument cluster should be

replaced through the exchange loop.
Fill out a damage report form and return

together with faulty instrument cluster.
Faulty units must always be returned in original

packaging.
The odometer and the Service Reminder

Indicator (SRI) of the replacement instrument
cluster can be adapted using the VAG1551
Scan Tool (ST) Page 01-133 .
01-84
On Board Diagnostic (OBD), initiating

program
Additional information

Component Locations
Service tools handbook
Parts catalog
01-85
Safety precautions
If special testing equipment is required

during road test, note the following:
WARNING!
Adhere to the following to avoid risk of

accident during measurements while driving
and road tests:
Only use VAS5051 or VAG1551 to read out

measuring value blocks. The tester must be
secured to the rear seat and operated from
there by a second technician.
To reduce the risk of personal injury and/or

damage of electric and electronic
components, always observe the following:
Always switch ignition off before connecting or

disconnecting test/measurement tools.
It is possible that the control module will

recognize a malfunction and store a DTC during
some tests. After completing all tests and
repairs, DTC memory should therefore be
checked and erased if necessary.
Always switch ignition off before disconnecting
or connecting battery. Failure to do so may

damage a control module.
01-86
Test requirements:
Check fuse for function according to wiring

diagram.
Always check coding of instrument cluster

according to code table Page 01-112 .
Connect VAS5051 tester or VAG1551 scan tool

Page 01-241 .
Switch on ignition.
Notes:
If nothing is indicated on display, check voltage

supply for VAG 1551 scan tool according to
wiring diagram.
Additional instructions can be called up via the

HELP button on the scan tool.
The button is used for advancing through the

program sequence.
An incorrect entry can be canceled using the C

button.
Function 00 "Automatic test sequence" can be

performed in operating mode 1 "Rapid data
transfer". This automatically checks all control
modules installed in the vehicle.
01-87
- Switch on ignition.
- Switch printer on via the PRINT button (indicator

lamp in button lights up).

operating mode 1.

Address word: 17
- Press buttons -1- and -7-.
Rapid data transfer Q Indicated on display:

17 - Instrument cluster
01-88
8D0920830... B5-INST. Clstr M73 D08

Indicated on display after approx. 5 seconds:
8D0920830...: Part number of instrument cluster (see also parts
catalog)
B5-INSTRUMENT CLUSTER component marking
VDO: Manufactured by VDO (M73 : Manufactured by Magneti
Marelli)
D08: Software version of instrument cluster
Coding 02242: Coding of instrument cluster
Note:
Check code number according to coding table Page 01-112 .
- Press button.
01-89
Rapid data transfer HELP If one of these messages is displayed, perform trouble shooting according
Control module does not answer to troubleshooting diagnostic.
Rapid data transfer HELP
Malfunction in communication setup

K-wire does not switch to Ground
K-wire does not switch to Plus
01-90

Select function XX
- Pressing the HELP button will print out an overview of all of the
possible functions.
02 - Check DTC Memory Page 01-91 .
03 - Output Diagnostic Test Mode Page 01-101 .
05 - Erase DTC Memory Page 01-107 .
06 - End Output Page 01-109 .
07 - Code Control Module Page 01-110 .
08 - Read Measuring Value Block Page 01-114 .
10 - Adaptation Page 01-133 .
01-91

02)
Note:
The displayed DTC information is updated only

when initiating OBD or with "Erase DTC Memory"
function 05.


Select function XX
- Press buttons -0- and -2-. This selects "Check DTC memory", function
02.

02 - Check DTC memory
X DTC recognized! The number of stored malfunctions appears in the display.
The stored malfunctions are displayed and printed out one after the
other.
- Check print-out against DTC table and repair malfunction Page 01-
93 .
01-92
No DTC recognized! If "No DTC recognized!" is displayed, the program will return to "Select
function XX" after the button is pressed.

Select function XX
Operating instructions of Scan Tool (ST)
- End Output (function 06) Page 01-109

- Switch off ignition and disconnect diagnostic connector.
01-93
Diagnostic Trouble Code (DTC) table for instrument cluster
Notes:
The following table lists all malfunctions that can be recognized by the instrument cluster and printed out by the VAG1551
scan tool. The malfunctions are listed in order according to their 5-digit numbers.
DTC numbers appear only on the print-out.
Before replacing a component shown as faulty, check the wiring and connections to the component as well as the Ground
(GND) connections according to wiring diagram.
After repairs and function test of the system, DTC memory must always be checked again using the VAG1551 scan tool
and erased.
DTC memory stores all static and sporadic malfunctions: If a malfunction occurs and persists for at least 2 seconds, it is
identified as a static malfunction (outside temperature malfunction at least 60 seconds, coolant temperature sensor only
after at least 30 minutes with engine running). If a malfunction does not occur again, it is registered as sporadic. "/SP" will
appear at right on scan tool display.
only register as static malfunctions if they still occur after testing.
Sporadic malfunctions which no longer occur during 50 driving cycles (ignition on at least 5 minutes, vehicle speed 30
km/h) are erased automatically.
01-94
VAG 1551 scan tool display Possible causes Corrective action

00562 Open circuit or short circuit - Locate malfunction using wiring diagram
between oil level thermal sensor
Oil level thermal sensor - -G266- and instrument cluster - Repair open circuit
G266-
Oil level thermal sensor -G266- - Oil level thermal sensor -G266- faulty Replace -
faulty -G266- faulty G266-
Open circuit/short circuit to
B+ Electronic part in sensor faulty
Short circuit to Ground
Implausible signal
00667 Open circuit or short circuit - Locate malfunction using wiring diagram
between instrument cluster and
Outside temperature signal A/C control head -E87- - Repair open circuit
A/C control head -E87- faulty - A/C system OBD

Open circuit/short circuit to
B+
Repair Manual, Heating & AirConditioning, Repair
Short circuit to Ground Group 01
implausible signal (is
indicated incorrectly and
must be disregarded)
00668
Battery was disconnected - Perform automatic test sequence in order to
determine the control module responsible for the
Vehicle voltage, terminal 30 Open circuit or short circuit to a DTC check voltage supply of malfunctioning
control module or sensor control module
Voltage supply too low
- Locate malfunction using wiring diagram
- Repair open circuit

- Erase DTC memory and observe vehicle further
01-95
VAG 1551 scan tool Possible causes Corrective action

display
00771 Open circuit or short circuit between sender for fuel - Locate malfunction using wiring
gauge -G- (Front Wheel Drive/All Wheel Drive) and diagram
Sender for fuel gauge -G- instrument cluster
Open circuit/short Sender for fuel gauge -G- (Front Wheel Drive/All
Wheel Drive) is faulty - - Replace Sender for fuel gauge -
circuit to B+ G- (Front Wheel Drive/All Wheel
Short circuit to Ground Drive)
00779 - Locate malfunction using wiring

Open circuit or short circuit
diagram
Outside air temperature Outside air temperature sensor -G17- faulty
sensor -G17- - Repair open circuit
- Replace outside air temperature
Open circuit/short sensor -G17-
circuit to B+
01039 Open circuit or short circuit between Engine Coolant - Locate malfunction using wiring
Temperature (ECT) sensor -G2- and instrument diagram
Engine Coolant cluster
Temperature (ECT) sensor - Repair open circuit
-G2- Engine Coolant Temperature (ECT) sensor -G2-
faulty - Replace Engine Coolant
Temperature (ECT) sensor -G2-
Open circuit/short
circuit to B+
01-96

display
01300
Open circuit or short circuit - Locate malfunction using
wiring diagram
Control module for Incorrect control module, that is, control module does
navigation with CD not support CAN - Repair open circuit
mechanism -J401-
A control module that supports CAN is not indicated with - Replace control module with
a "1" in measuring value block Page 01-132 If control a control module that supports
no communication module for navigation with CD-mechanism -J401- is not CAN
displayed with "1"
- Select adaptation channel 62
Adaptation for the instrument cluster was not performed and input the correct
properly adaptation value Page 01-
190 .
01304
Open circuit or short circuit - Locate malfunction using
wiring diagram
Radio Incorrect control module, that is, control module does
not support CAN - Repair open circuit
no communication A control module that supports CAN is not indicated with - Replace control module with
a "1" in measuring value block Page 01-132 . a control module that supports
CAN
Adaptation for the instrument cluster was not performed
properly - Select adaptation channel 62
and input the correct
adaptation value Page 01-
190 .
01-97
VAG 1551 scan Possible causes Corrective action

tool display
01311 Open circuit or short circuit to a control module in - Locate malfunction using wiring diagram
information data-BUS
Data-BUS - Repair open circuit
information Incorrect control module in information data-BUS,
that is, control module does not support CAN. - Replace control module with a control
module that supports CAN
faulty A control module that supports CAN is not indicated
with a "1" in measuring value block Page 01-132 . - Select adaptation channel 62 and input
in single wire the correct adaptation value Page 01-
mode During adaptation of the instrument cluster, a control 190 .
module that supports CAN was not concurrently
adapted - Check data exchange Page 01-196 .
Data bus is operating on only one wire (this can

cause EMV problems)
01-98

display
01312 Open circuit or short circuit to a control module in - Locate malfunction using wiring
powertrain data-BUS diagram
Powertrain data-BUS
A control module in the powertrain data-BUS is incorrect, - Repair open circuit
faulty that is, control module does not support CAN
- Replace incorrect control module
A control module that supports CAN is not indicated with a with a control module that supports
"1" in measuring value block Page 01-129 . CAN
During adaptation of the instrument cluster, a control - Select adaptation channel 60 and
module that supports CAN was not concurrently adapted input the correct adaptation value
Page 01-183 .
01314
Open circuit or short circuit - Locate malfunction using wiring
diagram
Engine Control Incorrect control module, that is, control module does not
Module (ECM) support CAN - Repair open circuit
A control module that supports CAN is not indicated with a - Replace control module with a
no communication "1" in measuring value block Page 01-129 If Engine control module that supports CAN
Control Module (ECM) is not displayed with "1"
- Select adaptation channel 60 and
Adaptation for the instrument cluster was not performed input the correct adaptation value
properly Page 01-183 .
01-99

display
01315
diagram
Transmission Control Incorrect control module, that is, control module does not
Module (TCM) support CAN - Repair open circuit
A control module that supports CAN is not indicated with - Replace control module with a
no communication a "1" in measuring value block Page 01-129 . control module that supports CAN
Adaptation for the instrument cluster was not performed - Select adaptation channel 60
properly and input the correct adaptation
value Page 01-183 .
01320
diagram
Climatronic control Incorrect control module, that is, control module does not
module -J255- support CAN - Repair open circuit
A control module that supports CAN is not indicated with - Replace control module with a
no communication a "1" in measuring value block Page 01-130 If control module that supports CAN
climatronic control module -J522- is not displayed with "1"
- Select adaptation channel 60
Adaptation for the instrument cluster was not performed and input the correct adaptation
properly value Page 01-183 .
01-100
VAG 1551 scan Possible causes Corrective action

tool display
01336 Open circuit or short circuit to a control module in - Locate malfunction using wiring diagram
comfort system data-BUS
Comfort system - Repair open circuit
data-BUS A control module in the comfort system data-BUS
is incorrect, that is, the control module does not - Replace control module with a control
support CAN module that supports CAN
faulty
A control module that supports CAN is not - Select adaptation channel 61 and input the
in single wire correct adaptation value Page 01-187 .
mode indicated with a "1" in measuring value block
Page 01-131 . - Check data exchange Page 01-196 .
During adaptation of the instrument cluster, a
control module that supports CAN was not
concurrently adapted
Data bus is operating on only one wire (this can
cause EMV problems)
01402
Open circuit in clock, enable or data wire - Check cabling of data wires for damage
Data wire from Problem in interface between navigation and - Check for cause of electromagnetic
navigation instrument cluster disturbance
Disturbance due to electromagnetic radiation
Unplausible Repair Manual, Radio,
inside and outside vehicle
signal Telephone,Navigation, Repair Group 91
65535 Instrument cluster faulty - Replace instrument cluster Page 90-27 .

Control module
faulty
01-101

function 03)
Notes:
Output Diagnostic Test Mode is only possible

when vehicle is stationary and engine is not
running!
If malfunctions are found during output

Diagnostic Test Mode, determine cause of
malfunction and replace instrument cluster if
necessary.
During the "output Diagnostic Test Mode"

function, all actuators that are installed in the
instrument cluster and coded are activated in
sequence.
There is also a simultaneous parallel sweep

through the indicator range of all analog display
instruments (Engine Coolant Temperature
(ECT) gauge, tachometer, speedometer, fuel
gauge)
Activation of warning lamps
Activation of seat belt warning light
Activation of chime
Segment test of driver information system, LCD

clock/date display, and LCD trip odometer and
daily odometer.
01-102
Test of instrument cluster lighting, including

dimmer
Note:
Test can only be performed with lights switched

on.
Initiating output Diagnostic Test Mode:

Select function XX
- Press buttons -0- and -3-. This selects "output Diagnostic Test Mode
(DTM)", function 3.

- Press -Q- button to confirm input. Output Diagnostic Test Mode for
analog displays is initiated immediately.
Output Diagnostic Test Mode Indicated on display:

Analog displays
01-103
The following tests are performed

simultaneously:
Sweep of coolant temperature needle through

entire display range
Sweep of tachometer needle through entire

display range
Sweep of speedometer needle through entire

display range
Sweep of fuel gauge needle through entire

display range
After sweep of display ranges, the following fixed

values are displayed:
Engine Coolant Temperature (ECT) 1/

2
gauge:
Tachometer: 3000 RPM
Speedometer: 62 MPH
Fuel gauge: 1/
2
Note:
Switching ignition on and off will stop any needle
sweep that has started.
- Press button.
01-104

Warning lamp test for instrument cluster
All lamps are switched on that are activated by the processor.
- Press button.

Seat belt warning light -K19
Seat belt warning light is activated.
Note:
Depending on options/versions, the seat belt warning light may be

activated by the control module coding, that is, if this actuator test is
omitted, the warning light is not active.
- Press button.
01-105

Gong
Chime is activated and sounds the entire time.
- Press button.

Segment test
All display points of the driver information display, the LCD clock/date
indicator and the LCD odometer and daily odometer are activated.
- Press button.
01-106

Illumination/switch and instruments
Instrument cluster illumination is automatically set twice to bright and dark
and then switched to maximum illumination (bright).
- Press button.

END
- Press button to end output Diagnostic Test Mode.
The tester returns to the "Select function" mode.

Select function XX
01-107
Erase DTC Memory (scan tool function

05)
Note:
If DTC memory cannot be erased, check DTC

memory again and repair malfunction.
Requirements
DTC memory checked Page 01-91 .
All malfunctions repaired.
After successful DTC memory check:

Select function XX
- Press buttons -0- and -5-. This selects "Erase DTC memory", function
05.
01-108

05 Erase DTC memory

DTC memory is erased!
DTC memory is erased.
- Press button.

Select function XX
Notes:
CAUTION!
Test sequence is faulty if this message is displayed.
DTC memory was not checked
Rapid data transfer

Test sequence is faulty if this message is displayed.
Follow test sequence exactly: first check DTC memory, repair malfunction
(s) if necessary, then erase.
01-109
End Output (scan tool function 06)

Select function XX
- Press buttons -0- and -6-. This selects "End Output", function 06.

06 End output

Input address word XX
- Switch off ignition.
- Disconnect harness connectors for the VAG1551 scan tool
01-110

07)
Using this function, the instrument cluster can be

coded as follows:
Options
Country versions
Number of cylinders
Engine versions
Notes:
Coding adjusts the various combination

possibilities of the on board computer according
to engine type, cylinder count and country
version.
Only the appropriate combinations for the Audi

A4 or Audi S4 are mentioned in the coding
table.
01-111
Initiating coding

Select function XX
- Press buttons -0- and -7-. This selects "Code Control Module", function
07.

07 Code control module
Code control module Indicated on display:

Input code number XXXXX (0-32000)
- Input code number using coding table Page 01-112 . Example:
02242
02 Seat belt warning active
2 Country version US
4 4-cylinder
2 gas engine
Code control module Q Indicated on display:

Input code number 02242 (0-32000)
8D0920830... B5-INST. Clstr. M73 D08

Indicated on display:
- Press button.
01-112
Coding table:
XX Optional equipment/transmission
version
00 No additional equipment
02 Seat belt warning active
16 Navigation I and II
X Country version
0 Germany (D)
1 RdW Left Hand Drive
2 USA (US)
3 Canada (CDN)
4 Great Britain (GB)
5 Japan (JP)
6 Saudi Arabia (SA)
7 Australia (AUS)
8 RdW Right Hand Drive
9 JP Right Hand Drive (RHD)

vehicles
Note:
Navigation I is the first generation navigation

system in center display. Navigation II is the
navigation system with the monitor in the center
console.
01-113
X Cylinder count
4 4-cylinder
6 6-cylinder
X Engine versions
0 TDI-engine
2 gas engine
4 Turbo-engine
Notes:
Coding can be modified to allow for various

combinations of optional equipment, depending
on what is installed in the vehicle.
If vehicle is equipped with more than one item

of optional equipment and/or transmission
variant that needs to be coded, the overall
coding will be the total of the individual coding
numbers.
Example:
Seat belt warning active and navigation I 02

+ 16 = 18
01-114

function 08)
Initiating "Read Measuring Value Block"

Select function XX
- Press buttons -0- and -8-. This selects "Read measuring value block",
function 08.

08 - Measured value block
Read measured value block Indicated on display:

- Enter display group number (from table Page 01-115 ) and press -Q-
The selected measuring value block is now displayed in standard form.
01-115
Display group overview:
Display group Indicated on display

number
001 1 = Speed
2 = Engine RPM
3 = Oil pressure switch
4 = Time
002 1 = Trip odometer
2 = Fuel gauge
3 = Tank sensor
4 = Outside air
temperature
003 1 = Coolant temperature
010 1 = Channel 30
2 = Adaptation tank
sensor
3 = Channel 9
4 = Trip odometer
011 1 = Channel 4
2 = Language version
3 = Channel 3
4 = Consumption display
01-116

number
012 1 = Channel 40
2 = distance since service
3 = Channel 41
4 = Time since service

013 1 = Channel 42
2 = Minimum value miles
3 = Channel 43
4 = Maximum value miles

014 1 = Channel 44
2 = Max. time interval
3 = Unassigned
4 = Unassigned
015 1 = Channel 45
2 = Oil quality
3 = Channel 46
4 = Total consumption
quantity
01-117

number
050 1 = Trip odometer
2 = Engine RPM
3 = Oil temperature
4 = Coolant temperature
125 1 = Engine
2 = Transmission
3 = ABS
4 = ADR
126 1 = A/C
130 1 = Tire pressure
2 = Auxiliary heater
3 = Unassigned
4 = Parking assistance
140 1 = Radio
2 = Telephone
3 = Navigation
4 = Telematic (Tele-data-
processing)
01-118
Notes:
For an instrument cluster replacement, data

from display groups 10...15 must be printed out.
Measuring value blocks 125 and 126 indicate

the participants in the powertrain data-BUS.
Measuring value block 130 indicates the

participants in the comfort system databus.
Measuring value block 140 indicates the

participants in the information data-BUS
Display will always indicate the actual values

obtained from the sensors. The values which
appear on the instrument cluster are filtered
and may be different.
If the actual engine coolant temperature is

between 80 C and 100 C, instrument cluster
will always show 90 C.
01-119
Measuring value block 001
Read Measuring Value Block 1 Indicated on display:

30 MPH 2400 RPM Oil p2 <min. 12: 20 h
Time
Oil pressure switch 2
Oil p2 < min.
Oil p2 OK
Engine speed (RPM)
0 - 9990 RPM
Speed
0 - 187 MPH
01-120

6256 mi 43 l 82 Ohm 23.0 C
Outside air temperature
-40 to +70 C
Tank sensor
approx. 280 Ohm (empty) ... approx. 40 Ohm (full)
Fuel gauge
0 - 100 1
Display value of trip odometer
01-121

85.0 C
Coolant temperature
50 - 130 C
01-122

Channel 30 128 Channel 9 626 mi
Input value for adaptation of odometer
Adaptation channel for odometer
Factory adjusted adaptation value
Adaptation channel of fuel gauge sender resistance range
Note:
If the value "128" in display field 2 was changed due to a customer complaint, the changed value must be transferred when
replacing instrument cluster.
01-123

Channel 4 2 Channel 3 100
Factory adjusted adaptation value
Adaptation channel of fuel gauge
Selected language
1 is German
2 is English
Adaptation channel for language version of driver information display
Note:
If the value "100" in display field 4 was changed due to a customer complaint, the changed value must be transferred when
replacing instrument cluster.
01-124

Time expired
For example, 10 means 10 days
Adaptation channel for time since service

Driven miles
8 means 800 miles
Adaptation channel for distance driven since service
01-125

Maximum mileage
8 means 8000 miles1)

Adaptation channel for maximum mileage
Minimum mileage performance2)
8 means 8000 miles1)

Adaptation channel for minimum mileage
Note:
1) The currently valid specifications can be found in the "Maintenance" book.
Repair Manual, Maintenance
2)For USA-vehicles: For instrument cluster of the manufacturer Marelli, the starting value (first value of remaining distance
without calculating) is set to 8000 miles. For instrument clusters of the manufacturer VDO, the starting value is set to 8100
miles. The 100 miles which are displayed in excess, are compensated during driving. For vehicles with 1.8 Liter Turbo engine,
the starting value of 5000 is set. For both manufacturers 8000 or 8100 miles is displayed anyway. The damper action also
occurs from the actual remaining interval during driving operation.
01-126

Channel 44 365
Maximum time interval
365 means 365 days/1 year1)

Adaptation channel for maximum time interval
Note:
01-127

Total consumption quantity
300 means 300 liters
Adaptation channel for the total consumption quantity (gasoline engines only)
Oil quality
Input of 1 to 4 possible 1)
The "1" is entered in the USA
Adaptation channel for oil quality
Notes:
Oil quality must be re-adapted after every service.
01-128

6256 mi 2400 RPM 99 C 85.0 C
Coolant temperature
50 - 130 C
Oil temperature
Engine speed (RPM)
0 - 9990 RPM
Display value of trip odometer
01-129
Read Measuring Value Block Indicated on display:

125
Engine 1 Transmission 1
ADR - Display field for connecting powertrain data-BUS
1 - means the ADR control module is a participant in the powertrain data-BUS

empty display field indicates ADR control module is not a participant in the
powertrain data-BUS
ABS - Display field for connecting powertrain data-BUS
1 - means the ABS control module is a participant in the powertrain data-BUS

empty display field indicates ABS control module is not a participant in the
powertrain data-BUS
Transmission - Display field for connecting powertrain data-BUS
1 - means the Transmission Control Module (TCM) is a participant in the powertrain

data-BUS
empty display field indicates Transmission Control Module (TCM) is not a participant
in the powertrain data-BUS
Engine - Display field for connecting powertrain data-BUS
1 - means the Engine Control Module (ECM) is a participant in the powertrain data-BUS
empty display field indicates Engine Control Module (ECM) is not a participant in the powertrain data-
BUS
01-130

A/C 1
A/C - Display field for connecting powertrain data-BUS
1 - means the A/C control module is a participant in the powertrain data-BUS

empty display field indicates A/C Control Module is not a participant in the powertrain data-
BUS
01-131
Read Measuring Value Indicated on display:

Block 130
Parking assistance - display field for connecting comfort system data-BUS.
Connection
1- means the parking assistance control module is a participant in the comfort

system data-BUS
empty display field means the parking assistance control module is not a participant
in the comfort system data-BUS
Auxiliary heater - display field for connecting the comfort system data-BUS
1- means the auxiliary heater control module is a participant in the comfort system data-BUS
empty display field means the auxiliary heater control module is not a participant in the comfort
system data-BUS
Tire pressure - display field for connecting the comfort system data-BUS
1- means the tire pressure control module is a participant in the comfort system data-BUS
empty display field means the tire pressure control module is not a participant in the comfort system data-
BUS
01-132
Read Measuring Value Indicated on display:

Block 140
Telematic - Display field for connecting information data-BUS
1 - means the Telematic control module is a participant in the information data-

BUS
empty display field indicates Telematic control module is not a participant in the
Navigation - Display field for connecting information data-BUS
1 - means the navigation control module is a participant in the information data-BUS

empty display field indicates navigation control module is not a participant in the
Telephone - Display field for connecting information data-BUS
1 - means the telephone control module is a participant in the information data-BUS

empty display field indicates telephone control module is not a participant in the information
data-BUS
Radio - Display field for connecting information data-BUS
1 - means the radio control module is a participant in the information data-BUS
empty display field indicates radio control module is not a participant in the information data-BUS
01-133
Adaptation (scan tool function 10)
Individual functions are called up by entering the

appropriate adaptation channel numbers (listed
in the adaptation table Page 01-134 ).
Notes:
Using measuring value blocks 10, 11, 12 and

15, the values that need to be transferred to the
new instrument cluster can be read out before
replacement.
Adaptation channels 42, 43, and 44 (see

measuring value blocks 013 and 014 Page
01-125 and Page 01-126 ) must be adapted
according to the oil quality (measuring value
block 15 Page 01-127 ).
Adaptation channels 60, 61, and 62 are only

needed when the instrument cluster
communicates with the corresponding BUS
system..
Measuring value blocks 125 and 126 Page

01-129 and Page 01-130 indicate the
components that are part of the powertrain
data-BUS.
Measuring value block 130 Page 01-131
indicates the components that are part of the

comfort system data-BUS.
Measuring value block 140 Page 01-132

indicates the components that are part of the
information data-BUS.
01-134
Adaptation table:
Adaptation channel Adaptation function

02 Resetting SRI after service Page 01-136
03 Adaptation of fuel gauge Page 01-140
04 Language version of driver information display Page 01-143
09 Odometer Page 01-148
18 Adaptation of auxiliary heater Page 01-152
30 Adaptation of fuel gauge sender resistance range Page 01-155
35 Adaptation of engine speed threshold Page 01-158
40 Adaptation for distance driven since service Page 01-161
41 Adaptation for time since service Page 01-164
42 Adaptation for minimum mileage performance Page 01-167
43 Adaptation for maximum mileage performance Page 01-170
44 Adaptation for maximum time interval Page 01-173
45 Adaptation for oil quality Page 01-176
46 Adaptation for total consumption quantity (only gasoline engines) Page 01-179
60 Adaptation powertrain data-BUS Page 01-181
61 Adaptation comfort system data-BUS Page 01-185
62 Adaptation information data-BUS Page 01-188
01-135
Initiating "Adaptation" function 10

Select function XX
- Press buttons -1- and -0-. This selects "Adaptation", function 10.

10 - Adaptation
Adaptation Indicated on display:

Input channel number XX
- Enter desired adaptation channel (adaptation table Page 01-134 ).
Note:
After changing an adaptation value or ending an adaptation channel,

"Adaptation" function 10 must be performed again before selecting
another adaptation channel.
01-136
Resetting SRI after service

Select function XX
- Press -1- and -0- and confirm by pressing the -Q- button.

10 - Adaptation

Notes:
The Service Reminder Indicator (SRI) is used to remind the driver
when a service is necessary. Indication is in center display.
Service reminder appears 1 month or 1200 miles before service limit
is reached. Resolution is 100 miles. Example for display: After a total
driving distance of 7000 miles, "SERVICE IN 1000 miles" is indicated.
01-137
The remaining distance to service can be

checked via the menu in center display by
pressing the clock set button once.
When a service event arrives, the text

information appears in the center display for 5
seconds when ignition is switched on. It is
shown after the note for automatic transmission
and a target input for navigation (if applicable).
Display: "SERVICE".
The currently valid specifications can be found

in the "Maintenance" book.
Data version of instrument cluster Page 01-

88 .
Channels 40, 41, and 46, which display the

dynamic values of the service event are set to
"0" automatically.
01-138
Channel 2 Adaptation 1 Indicated on display: Service event is displayed
- 1 3-
1 - means service is active, this means that "SERVICE!" is displayed in
the instrument cluster.
- Press button.
Channel 2 Adaptation 1 Indicated on display:

Input adaptation value XXXXX
Service event is reset using the following adaptation values:
Adaptation value Service event

00000 Reset
- Using the keypad enter the appropriate adaptation value (00000) to
erase the service.
- Press -0- button five times.
01-139
Channel 2 Adaptation 1 Q Indicated on display:

Input adaptation value 00000

- 1 3-
0 - means service is reset, meaning that "SERVICE in 8000 mi (Marelli
instrument cluster) or 8100 mi (VDO instrument cluster)" is displayed in
instrument cluster after confirming with Q button.
Note:
The display of 8000 or 8100 miles is the starting value for the service
display.

Store changed value?

- Press the button to complete the reset of the SRI.
01-140
Adaptation of fuel consumption display

Select function XX

10 - Adaptation

Notes:
Adaptation only for vehicles with on board computer.
Value entered must be between 85% and 115%.
Value must be entered in steps of 5%.
If the value "100" was changed due to a customer complaint, the
changed value must be transferred when replacing instrument cluster.
Consumption display - 1 3-
- Press button.
01-141
Note:
Correction of fuel consumption display is only

possible via direct input.

- Input desired correction value using scan tool keypad, filling initial
positions with "0".
Example:
Desired input value: 90%
Keypad input: 00090


Consumption display - 1 3-


Changed value is stored
-
Conclude adaptation of the fuel consumption display by pressing the
button.
01-142

Select function XX

10 - Adaptation
Note:
If input is incorrect, tester switches to function mode.
Function is unknown or cannot

be carried out at the moment
- Press button.
- Select "Adaptation" function 10 again and select adaptation channel
03.
- Perform correction of fuel gauge again.
01-143
Language version of driver information

display

Select function XX

10 - Adaptation

Language - 1 3- Notes:
Display indicates only the last digit of the five digit language version
code, for example, 1 for German.
If incorrect value is input "Adaptation" function is terminated and
"Adaptation" function 10 must be initiated again.
Code can now be entered using the scan tool keypad in steps or via
direct input.
01-144
Coding table:
Code Language version

00001 German
00002 English
00003 French
00004 Italian
00005 Spanish
00006 Portuguese
01-145
Input in steps:
- Code can be decreased using button 1 and

increased using button 3, for example, to 2 for
language version English.

Language - 1 3-


- Conclude adaptation of language version by pressing the button.
01-146
Direct input:
Language - 1 3-
- Press button.

- Input desired five digit code Page 01-144 Enter using keypad.
Example:
Coding: 2 (English)
Input value: 00002

01-147

Language - 1 3-


- Conclude adaptation of language version by pressing the button.
01-148
Odometer display
This function is used to adapt the odometer after

the instrument cluster is replaced.
Notes:
The adaptation is only possible for an

instrument cluster with a maximum mileage of
100 miles.
Adaptation can only be performed once for

each instrument cluster.
Only larger adaptation values can be entered

(more than 100 miles).
If an incorrect value is entered and confirmed, it

cannot be changed. If this happens, the
instrument cluster must be replaced.
In countries where speedometers are calibrated

in miles, adaptation can be performed in miles.
Observe notes when replacing instrument

cluster Page 01-191 .
01-149
Rapid data transfer HELP Indicated on display:

Select function XX
- Press buttons -1- and 1-. This selects "Login Procedure" function 11.

11 - Login-Procedure
Login-Procedure Indicated on display:

Input code number XXXXX
- Input code number 13861.
Login-Procedure Q Indicated on display:

Input code number 13861

Select function XX

10 - Adaptation

01-150

Mileage in 10 miles - 1 3- Note:
For the VAG1551 scan tool values can only be input via direct input.
- Press the button to continue program sequence.

- Input adaptation value (measuring value block 10 Page 01-122 ) via
the keypad.
Example:
Mileage = 89627
08963
X Hundred thousands: 100000 - 655350

X Ten thousands: 10000 - 90000
X Thousands: 1000 - 9000
X Hundreds: 100 - 900
X Tens: 10 - 90
Ones: round to nearest ten
01-151


Mileage in 10 miles - 1 3-


- End adaptation of odometer by pressing the button.
01-152
Adaptation of auxiliary heater

Select function XX

10 - Adaptation

- Press buttons 1- and -8-.
01-153
Channel 18 Adaptation 0
- Indicated on display: Adaptation value is displayed, for example 0.
- 1 3-
Notes:
Adaptation value "0" is input if auxiliary heater is not installed.
Adaptation value "1" is input if an auxiliary heater is installed that is
independent of engine condition (running or not).
Adaptation value "10" is input if an auxiliary heater is installed that
switches off when engine is not running.
- Press button.

- Input adaptation value using keypad, filling initial positions with "0", for
example 00001.

01-154

- 1 3-


- End adaptation of the auxiliary heater by pressing the button.
01-155
Adaptation of fuel gauge sender resistance

range
This function is used to adjust the fuel gauge

sender resistance range if the fuel gauge display
in the instrument cluster does not match the
actual amount of fuel in the tank.

Select function XX

10 - Adaptation

01-156
Channel 30 Adaptation 128 Indicated on display: Adaptation value is displayed, for example 128.
Tank sender - 1 3- Notes:

"128" is the adaptation value for the standard resistance range for the
fuel gauge sender as set by the factory.
The resistance value for the fuel gauge sender resistance range can
be adjusted by 8 Ohm to give an adaptation value between 120 and
136.
- Press button.

- Input desired correction value using scan tool keypad, filling initial
positions with "0" and watch how the display responds.
Example:
Desired input value: 132
Keypad input: 00132

01-157

Tank sender - 1 3-


- End adaptation of the fuel gauge sender resistance range by pressing
the button.
01-158
Adaptation of the engine speed threshold
This function is used to adapt the offset value for

the engine speed threshold to the dynamic oil
pressure warning.

Select function XX

10 - Adaptation

- Press buttons -3- and 5-.
01-159
Channel 35 Adaptation 0 Indicated on display: Adaptation value is displayed, for example 0.
- 1 3- Notes:
The adaptation value of 0 corresponds to the value set at the factory
for the oil pressure warning if the oil pressure drops below 1.2 bar at
1500 rpm.
The adaptation can be performed in four steps (0-1000).
The adaptation value of "250" changes the engine speed threshold to
1750 rpm.
- Press button.

- Input adaptation value using keypad, filling initial positions with "0", for
example, 00250.

01-160

- 1 3-


- End adaptation of the engine speed threshold by pressing the
button.
01-161
Distance driven since service
This function is used to input the distance in

miles since the last service.

Select function XX

10 - Adaptation

Channel 40 Adaptation 8 Indicated on display: The display indicates the number of miles driven
since the last service (here for example, 8 indicates 800 miles)
Actual value Insp. in 100 Miles - 1 3-
01-162
Notes:
Input of current specified value is only possible

in units of 100 miles, therefore indication in
display also changes in 100 mile units.
Observe notes when replacing instrument

cluster Page 01-191 .
Values can only be input directly using the scan

tool keypad.
Multi-function steering wheel, On Board Diagnostic (OBD) Page 1 of 25
01-84
Multi-function steering wheel,

On Board Diagnostic (OBD)
General notes
Technical features of the multi-function

steering wheel
The multi-function steering wheel enables the

radio to be operated from the steering wheel (the
most important functions) and contains an
extensive On Board Diagnostic (OBD).
The control module for the multi-function steering

wheel is equipped with a DTC memory. When
malfunctions occur in monitored components or
wiring, Diagnostic Trouble Codes (DTCs) are
stored in DTC memory with a description of the
malfunction type.
01-85
On Board Diagnostic (OBD), initiating

program

Technical service handbook.
Parts catalog
01-86
Safety precautions
If special testing equipment is required

during test drive, note the following:
WARNING!
To reduce the risk of accidents observe the

following:
During a road test in an airbag-equipped

vehicle, the VAS5051 tester or the VAG1551
scan tool must always be fastened to and
operated from the rear seat by a second
technician.
01-87
To reduce the risk of injury to people and or

damage to the electrical system and
components, observe the following:
Always switch ignition off before connecting or

disconnecting test/measurement tools.
It is possible that the control module will

recognize a malfunction and store a DTC during
some tests. Therefore, after completing all tests
and repairs, check and if necessary erase the
DTC memory.
Always switch ignition off before disconnecting

or connecting the battery. Failure to do so may
damage a control module.
01-88
Test requirements
Check fuse for function according to wiring

diagram.
Connect VAS5051 tester or VAG1551 scan tool

page 01-108 .
Switch ignition on.
Notes:
If nothing is indicated on display, check voltage

supply for VAG 1551 scan tool according to
wiring diagram.
Additional instructions can be called up via the

HELP button on the scan tool.
The button is used for advancing through the

program sequence.
An incorrect entry can be canceled using the C

button.
Function 00 "Automatic test sequence" can be

performed in operating mode 1 "Rapid data
transfer". This automatically checks all control
modules installed in the vehicle.
01-89


operating mode 1.

Address word for steering wheel electronics: 16

16 - Steering wheel electronics
01-90
4B0907487E Steering whl. electronics D00

4B0907487 E: Part number of steering wheel electronics - radio

operation (see also parts catalog)
Steering wheel electronics: component marking
D00: Software version of control module
- Press button.
Rapid data transfer HELP If one of these messages is displayed, carry out trouble shooting
Control module does not answer procedures according to the wiring diagram.
Error in communication link
K wire not switching to Ground
K wire not switching to B+
01-91

Select function XX
- Pressing the HELP button will print out an overview of all of the
possible functions.
- Press the button to continue program sequence.
01 - Check Control Module Versions page 01-92 .
03 - Output Diagnostic Test Mode page 01-97 .
08 - Read Measuring Value Block page 01-103 .
01-92

tool function 01)
Select function XX
- Press buttons -0- and 1-. This selects "Check control module" function
01.

4B0907487E steering whl. electronics D00

4B0907487 E: Part number of steering wheel electronics - radio

operation (see also parts catalog)
Steering wheel electronics: component marking
D00: Software version of control module
- Press button.
01-93

02)
Note:
The displayed DTC information is updated only

when initiating OBD or with "Erase DTC Memory"
function 05.


Select function XX
- Press buttons -0- and -2-. This selects "Check DTC memory", function
02.

X DTC recognized The number of stored malfunctions appears in the display.
The stored malfunctions are displayed and printed out one after the
other.
- Check printout against DTC table and repair all malfunctions as
necessary page 01-95 .
01-94
No DTC recognized If "No DTC recognized" is displayed, the program will return to "Select
function XX" after the button is pressed.

Select function XX
Scan Tool operating instructions
- End output (Function 06) page 01-102

- Switch off ignition and disconnect diagnostic connector.
01-95
Diagnostic Trouble Code (DTC) table
Notes:
The following list contains all malfunctions that can be recognized by the multi-function steering wheel and printed out by
the VAG1551 scan tool. The malfunctions are listed in order according to their 5-digit numbers.
DTC numbers appear only on the print-out.
Before replacing a component shown as faulty, check the wiring and connections to the component as well as the Ground
(GND) connections according to wiring diagram.
After repairs and function test of the system, DTC memory must always be checked again using the VAG1551 scan tool
and erased.
DTC memory stores all static and sporadic malfunctions: If a malfunction occurs and persists for at least 2 seconds, it is
identified as a static malfunction. If a malfunction does not occur again, it is registered as sporadic. "/SP" will appear at the
right of the scan tool display.
only register as static malfunctions if they still occur after testing.
Sporadic malfunctions which no longer occur during 50 driving cycles (ignition on at least 5 minutes, vehicle speed 30
km/h) are erased automatically.
The three digit malfunction type number appearing next to the DTC is a data code and can be ignored.
01-96
DTC Possible cause Corrective action
VAG1551 scan tool

display
01426
Control unit in steering Open circuit in wiring - no connection between - Locate malfunction using wiring
wheel -E221 interface and steering wheel diagram
No communication Unintelligible messages on CAN-bus (interface and

buttons in steering wheel are connected via a CAN- Electrical Wiring Diagrams,
Implausible signal bus) Troubleshooting & Component
Locations

- Check wires between interface and
steering wheel
65535
Control module Control module for multi-function steering wheel - - Replace control module for multi-
malfunctioning J453- faulty function steering wheel -J453-
Faulty
01-97
Output Diagnostic Test Mode (DTM)

(scan tool function 03)
Notes:
Output Diagnostic Test Mode is only possible

when vehicle is stationary and engine is not
running!
If malfunctions are found during output

Diagnostic Test Mode, determine cause of
malfunction and repair if necessary.
In the function " output Diagnostic Test Mode

(DTM)" functions of the system are checked
Perform Output Diagnostic Test Mode
- Switch on radio.
- Press buttons -0- and -3-. This selects "output

Diagnostic Test Mode (DTM)", function 3.

01-98
- Press the button.

Radio louder
The radio volume is increased audibly.
- Press the button.

Radio quieter
The radio volume is decreased audibly.
- Press the button.

Search radio stations upward
The next station will be searched and displayed in combination center
display.
- Press the button.
01-99

Search radio stations downward
The previous station will be adjusted again and will be displayed in
combination center display.
- Press the button.

End
- Press the button.
- The tester returns to the "Select function" mode.

Select function XX
01-100

05)
Note:

memory again and repair malfunction.
Requirements
DTC memory checked page 01-93
All malfunctions repaired
After successful DTC memory check:

Select function XX
- Press buttons -0- and -5-. This selects "Erase DTC memory", function
05.
01-101

05 Erase DTC Memory

DTC Memory is erased!
DTC memory is erased.
- Press the button.

Select function XX
Notes:
Attention!
This message indicates an error in the test sequence.
DTC Memory was not interrogated
Rapid data transfer

Follow test sequence exactly: first check DTC memory, repair malfunction
(s) if necessary, then erase.
01-102
- Press buttons -0- and -6-. This selects "End

Output", function 06.

06 - End output

- Disconnect harness connectors for the VAG1551 scan tool
01-103

function 08)
Initiating "Read Measuring Value Block"

Select function XX
function 08.


- Input display group number (from table page 01-104 ) and press -Q-
The selected measuring value block is now displayed in standard form.
01-104
Display group overview

number
001 1 = Lower button
2 = Louder button
3 = Memory downward
button
4 = Memory upward button

002 1 = Station buttons (preset)
backward
2 = Station buttons (preset)

forward
3 = Unassigned
4 = Unassigned
01-105

lower louder Memory backward Memory upward
Memory upward button
not operated
Memory upward
Memory downward button
not operated
Memory downward
Louder-button (increasing volume)
not operated
louder
Lower button (decreasing volume)
not operated
lower
01-106

activated activated
Station buttons (preset) forward
not operated
operated
Station buttons (preset) backward
not operated
operated
01-107
Multi-function steering wheel button

assignment
Radio button assignment
1 - Radio: Forward search function; Cassette: Fast forward; CD: Title

forward
2 - Radio: Backward search function; Cassette: Rewind; CD: Title
backward
3 - Station buttons (preset) b backward
4 - Increase volume
5 - Decrease volume
6 - Station buttons (preset) forward
Ultrasonic interior monitoring On Board Diagnostic (OBD) Page 1 of 44
01-108
Ultrasonic interior monitoring

On Board Diagnostic (OBD)
General Information
The ultrasonic interior monitoring system is only

offered in conjunction with the anti-theft system.
The security provided by the anti-theft system is

enhanced through addition of the ultrasonic
interior monitoring option.
Interior monitoring activates the anti-theft alarm

when unauthorized attempts are made to enter
the vehicle through the side windows.
Function
The ultrasonic interior monitoring system

consists of:
Control module for ultra-sound sensors -

J347-
Ultra-sound sensor, left for anti-theft warning

system -G170-
Ultra-sound sensor, right for anti-theft warning

system -G171-
Sensor for broken window glass rear left -G183-

(only for Avant)
Sensor for broken window glass rear right -

G184- (only for Avant)
Switch for passenger compartment monitoring -

E183-
01-109
The ultra-sound sensors in the right and left

upper B-pillar trims monitor the side windows and
send the monitoring signal to the control module
for ultra-sound sensors.
If the monitoring signal deviates from the norm,

the control module for interior monitoring
activates the alarm via the control module for the
anti-theft system.
In addition to the contact switches in the lock

units, glass break sensors in side windows as
well as the conductor loop in rear window, (only
for Avant), serve for securing the exterior of the
vehicle.
The control module for interior monitoring

activates the warning lamps next to the door
locking buttons. These warning lamps provide
further information regarding the interior
monitoring system.
Repair Manual, Electrical Equipment
Interior monitoring can be manually shut off for

the duration of a door closing via the switch for
interior monitoring.
Owner's Manual
The ultrasonic interior monitoring system is

capable of extensive On Board Diagnostic
(OBD). If malfunctions in component parts
develop, DTCs are stored in the DTC memory of
the control module. Malfunctions can then be
identified using the VAG1551 or VAG1552 scan
tools.
01-110
Ultrasonic interior monitoring On Board

Diagnostic (OBD), initiating
Requirements
Fuse OK according to wiring diagram
VAG1551 Scan Tool (ST) connected page

01-1
Anti-theft system not armed
Notes:
If the display remains blank, check VAG1551

voltage supply according to wiring diagram.
The scan tool HELP button can provide

additional operating instructions.
The button is used to advance through the

program sequence.
If an incorrect entry is made, press the -C-

button to escape.
01-111


operating mode 1.

Address word for interior monitoring: 45
- Press buttons -4- and -5- to insert "Int. Monitoring" address word 45.

45 - Int. Monitoring
4B0951173 Int. Monitoring D00

Indicated on display after about 5 seconds
- Press button.
Note:
A list of available functions is printed out when the HELP button is

pressed.
01-112
01 - Check Control Module Versions page 01-

123
03 - Output Diagnostic Test Mode page 01-

124 .
07 - Code Control Module page 01-131 .
08 - Read Measuring Value Block page 01-

133 .
10 - Adaptation page 01-135 .
01-113

02)
Note:
The DTC display information is updated only

when initiating the On Board Diagnostic (OBD) or
"Erase DTC Memory" function 05.

Carrying out "Check DTC Memory" function

02

Select function XX
- Press buttons -0- and -2- to select "Check DTC Memory" function 02.

X DTC recognized Display indicates the number of stored malfunctions.
The stored malfunctions are shown and then printed in series.

- Using malfunction print-out, refer to DTC table and repair malfunctions
page 01-115 .
01-114
No DTC recognized If the message "No DTC recognized" is displayed, the program can be
returned to the starting point by pressing the button.

Select function XX
- Erase DTC Memory (function 05) page 01-137 .

- Switch ignition off and Disconnect VAG1551 Scan Tool (ST) from Data
Link Connector (DLC).
01-115
Diagnostic Trouble Code (DTC) table, interior monitoring
Notes:
The following table lists all the DTCs that can be recognized by the control module for interior monitoring and printed out
by the VAG1551 Scan Tool (ST). The DTCs are listed in order according to their 5-digit numbers.
DTC 5-digit numbers appear only on the print-out from the scan tool.
Before replacing a component shown as malfunctioning, check wiring and connections to the component as well as the
Ground (GND) connections according to the relevant wiring diagram.
When a repair has been completed, the system should be armed and then disarmed. Then check and erase DTC memory
using the VAG1551 Scan Tool (ST).
DTC memory records all static and sporadic malfunctions. When a malfunction occurs, it is first identified as a static
malfunction. If it does not occur again it is registered as a sporadic malfunction, and the letters "/SP" appear at the right of
the display.
After system is armed, all existing malfunctions are automatically re-classified as sporadic malfunctions and will only be
registered as static malfunctions if they still occur after testing.
Sporadic malfunctions which no longer occur after 50 driving cycles are erased automatically.
The three digit malfunction type number appearing next to the DTC is a data code which may be disregarded.
01-116
DTC
display
01377
Left Ultra-Sonic Sensor for
ATW-G170
Short circuit to B+ Short circuit between -G170- and - Repair wiring according to wiring diagram.
control module -J347-
-G170- faulty Electrical Wiring Diagrams, Troubleshooting &
- Replace -G170-.
Repair Manual, Body Interior, Repair Group 70
Open circuit/Short Open circuit in wiring between -G170- - Repair wiring according to wiring diagram.
circuit to Ground and control module -J347-
-G170- faulty Electrical Wiring Diagrams, Troubleshooting &
- Replace -G170-.
Repair Manual, Body Interior, Repair Group 70
Incorrect Signal Malfunctions during activation of - Perform function test page 01-128 .
ultrasonic interior monitoring
01-117
DTC
display
01378
Right Ultra-Sonic Sensor
for ATW-G171
Short circuit to B+ Short circuit between -G171- and control - Repair wiring according to wiring diagram.
module for ultra-sound sensors -J347-
-G171- faulty Electrical Wiring Diagrams,
binder
- Replace -G171-.
Repair Manual, Body Interior, Repair

Group 70
Open circuit/Short Open circuit in wiring between -G171- and - Repair wiring according to wiring diagram.
circuit to Ground control module for ultra-sound sensors -J347-
-G171- faulty Electrical Wiring Diagrams,
binder
- Replace -G171-.

Group 70
Incorrect Signal Malfunctions during activation of ultrasonic - Perform function test page 01-128 .
interior monitoring
01-118
DTC
VAG 1551 scan Possible cause Corrective action
tool display
01379
Interior Monitor Wiring malfunction between switch for passenger - Repair wiring according to wiring
Switch-E183 compartment monitoring -E183- and control module for diagram.
ultra-sound sensors -J347-
-E183- faulty Electrical Wiring Diagrams,
Locations binder
Short circuit to - Replace -E183-.

Ground 1)
Group 68
01380
Alarm Via ATW Break in attempt at left-rear side window or after a function - Erase DTC memory.
Sensor rl test
- Perform function test page 01-128 .
False alarm
- Adapt sensitivity of sensors page
01-135 .
01381
Alarm Via ATW Break in attempt at right-rear side window or after a - Erase DTC memory.
Sensor rr function test
- Perform function test page 01-128 .
False alarm
01-135 .
1) A malfunction is stored if the Ground is connected for more than 1 minute.
01-119
DTC
display
01382
Alarm Via ATW Sensor Break in attempt at left-front side window or after a - Erase DTC memory.
fl function test
- Perform function test page 01-
False alarm 128 .
01-135 .
01383
Alarm Via ATW Sensor Break in attempt at right-front side window or after a - Erase DTC memory.
fr function test
- Perform function test page 01-
False alarm 128 .
01-135 .
01-120
V.A.G 1551 Scan Tool display Possible cause Corrective action

01384 1)
Alarm via glass break sensor Short circuit or open circuit in harness - Erase DTC memory
connectors or in wire connections between
(sensor for broken window glass rear glass break sensors and rear window heater - Repair wiring according to
left -G183-; sensor for broken window to control module for ultra-Sound sensors - wiring diagram
glass rear right -G184- and conductor J347-
loop for rear window heater) Electrical Wiring Diagrams,
ATS was triggered by a break-in attempt via Troubleshooting & Component
one of the side windows or the rear window. Locations binder
Conductor loop in one of the side windows or
rear window has an open circuit - Replace side window with the
interrupted conductor loop
False alarm
Repair Manual, Body Exterior;
Repair Group. 64; Side window
Avant, removing and installing
- Replace rear window with the

interrupted conductor loop
Repair Manual, Body Exterior;

Repair Group. 64; Rear window
Avant, removing and installing
1) Only for Avant
01-121
V.A.G 1551 Scan Tool display Possible cause Corrective action

01403 1)
Glass break sensors rear A short circuit or an open circuit occurs in the - Erase DTC memory
harness connectors or in the wire connections
(sensor for broken window glass rear between glass break sensors and rear window - Repair wiring according to
left -G183-; sensor for broken window heater to control module for ultra-sound sensors wiring diagram
glass rear right -G184- and conductor -J347- when setting ATS.
loop for rear window defroster) Electrical Wiring Diagrams,
A conductor loop of one of the side windows or Troubleshooting & Component
the rear window is interrupted during setting of Locations binder
the ATS
- Check conductor loop in
side windows and replace
side window if necessary
Repair Manual, Body

Exterior; Repair Group. 64;
Side window Avant, removing
and installing
- Check conductor loop in

rear window and replace rear
window if necessary
Repair Manual, Body

Exterior; Repair Group. 64;
Rear window Avant, removing
and installing
65535
Control Module Malfunctioning - Replace control module.
1) Only for Avant
01-122
Interior monitoring function test
- Open side window approx. 10 cm.
- Close all doors.
- Lock vehicle, which will set the anti-theft warning

system and the interior monitoring.
- Wait 30 seconds until all warning lamps in door

trim blink slowly in 2 second intervals (f = 0,5
Hz).
- Insert hand through window opening and hold in

proximity of sensor.
- If the interior monitoring is OK, alarm will be

triggered. An entry into DTC memory of control
module for central locking "1370; alarm via
interior monitoring" as well as to ultra-sound
control module "alarm via sensor for ATS, fl, fr,
rl, rr".
- Switch off alarm by unlocking vehicle.
- DTC must be checked and erased in DTC
memory of the respective control module
01-123

tool function 01)
- Press buttons -0- and -1- to select "Check

Control Module Versions" function 01.

4B0951173 Interior monitoring. D00 Indicated on display

4B0951173: Part No. of control module

Interior monitoring: system identification and variation
- The program can be returned to the starting point by pressing the
button.

Select function XX
01-124

function 03)
Notes:
The Output Diagnostic Test Mode may only be

performed with the vehicle stationary and the
engine not running.
Any malfunctions identified by the Output

Diagnostic Test Mode must be checked and
repaired.
Performing output Diagnostic Test Mode

(DTM):
Rapid data transfer HELPSelect function XX Indicated on display:
- Press buttons -0- and -3- to select "Output Diagnostic Test Mode
(DTM)" function 03.
Rapid data transfer Q03 - Output Diagnostic Test Mode Indicated on display:
The output DTM activates the following elements in sequence:
Warning lamps next to door locking button on driver-side or

passenger-side door
An anti-theft warning system alarm

Wiring for voltage supply to the ultra-sound sensors
Wiring for pulse signal to the ultra-sound sensors
01-125
Note:
No "ATS alarm" can be triggered via this output

Diagnostic Test Mode (DTM). To trigger a "ATS
alarm", perform the actuator test via the control
module for central locking page 01-91 or a
function test page 01-122 .
01-126
Carrying out "Output Diagnostic Test Mode"

function 03
- Press buttons -0- and -3- to select "Output

Diagnostic Test Mode" function 03.


Alarm System Indicator Light -K95
Warning lamps next to the door locking button at the driver-side or
passenger-side door are activated.
- Press button.

Create active alarm
The control module sends an alarm signal to the anti-theft system control
module for a signal test page 01-128 .
- Press button.

Voltage supply wire
The control module sends a constant voltage of 8 V to test the wiring
page 01-129 .
- Press button.
01-127

Wire for cycle signal
The control module sends a constant voltage of 5 V to test the wiring
page 01-130 .
- Press button.

END
- Press button.
The program is now back at its starting point.

Select function XX
01-128
Testing alarm signal
- Connect VAG1551 Scan Tool (ST) ( page 01-

1 ), and press buttons -4- and -5- to select "Int.
Monitoring" address word 45.
- Close all doors and open one side window.
- Lock vehicle by reaching through open window.

The anti-theft system horn confirms this, but
warning lamps do not light up.
- Wait 30 seconds until anti-theft system is

armed.
- Perform Output Diagnostic Test Mode ( page

01-124 ) and select control element test "Create
active alarm."
Notes:
It is also possible to test the alarm activation

signal without using the VAG1551 Scan Tool
(ST). To do this, carry out the first, third, fourth
and fifth procedure steps listed above.
The independent repair shop and the customer

can thereby test the functional capability of the
ultrasonic interior monitoring system.

Create active alarm
Specification: anti-theft system (turn signals and anti-theft horn) is
triggered.
01-129
- Shut off alarm by unlocking vehicle.
- End Output Diagnostic Test Mode (DTM).
- Initiate On Board Diagnostic (OBD) for anti-theft

system.
- Erase DTC memory page 01-137 .
Checking power supply wiring
- Remove both ultra-sound sensors.
Repair Manual, Body Interior, Repair Group

70, B-pillar trim , removing and installing
- Disconnect electronic harness connectors.
- Perform Output Diagnostic Test Mode ( page

01-124 ) and select output test "Power supply
wiring."

Power supply wiring
- Using multimeter (Fluke 83 or equivalent), measure voltage at wiring
harness connector between terminal 2 (B+) and terminal 3 (GND).
Specification: 8 V
- End output Diagnostic Test Mode (DTM).

- Install ultra-sound sensors again
- Erase DTC memory (function 05) page 01-137 .
- End output (function 06) page 01-139 .
01-130
Checking wiring for pulse signal
- Remove both ultra-sound sensors.
Repair Manual, Body Interior, Repair Group

70, B-pillar trim , removing and installing
- Disconnect electronic harness connectors.
- Perform Output Diagnostic Test Mode (DTM) (

page 01-124 ) and select control element test
"Signal pulse wire."

Signal pulse wire
- Using multimeter (Fluke 83 or equivalent), measure voltage at wiring
harness connector between terminal 1 (pulse signal) and terminal 3
(GND).
Specification: 5 V
- End Output Diagnostic Test Mode (DTM).
- Re-install ultra-sound sensors.
- Erase DTC memory (function 05) page 01-137 .
01-131

07)
This function can be used to code the interior

monitoring as follows:
Vehicle type: Audi A4
Arming mode of anti-theft system: dynamic

(m.y. 1997), or static (as of m.y. 1998)
Body version: Sedan/Avant
Notes:
The coding adjusts the control module for ultra-

sound sensors -J347- to meet the specific
requirements of the particular model version
and anti-theft alarm system.
The coding table gives only the coding

applicable to the Audi A4.
Carrying out "Code Control Module" function

07

Select function XX
- Press buttons -0- and -7- to select "Code Control Module" function 07.

07 - Code Control Module
01-132
Code Control Module Indicated on display

- Enter code number:
Coding: 00101
00 Place holders, disregard
1 Audi A4
0 Arming mode static
1 Sedan
2 Avant
Code Control Module Q

- Indicated on display
Enter code number 00101 (0-32000)
4B0951173 Interior monitoring D02 Indicated on display

- End coding by pressing button.

Select function XX
This will end the function.

06 - End Output
01-133

function 08)
Carrying out "Read Measuring Value Block"

function 08

Select function XX
function 08.


- Press buttons -0-, -0- and -1- to input display group number 1 (001).
The selected measuring value block is now indicated in standard format.

Evaluation page 01-134 .
01-134
Read Measuring Value Block, overview
Display group 001
Indicated on Display Display value Identification

Read Measuring Value Block 1 0100 1) 1 = switch positions
1234 100% 1) 2 = sensitivity of the sensors
3 = not assigned
4 = not assigned
1) Example of display.
Display value table
1 2
Switch for Int. Monitoring: : pressed = 1, not pressed = 0 50 ... 100% 3)
Driver-side door contact switch : driver-side door open = 1, driver-side door closed = 0
: armed = 1, not armed = 0
Anti-theft warning system: : present = 1, not present = 0
Glass breakage system 2):
2) Avant only.
3) Refer to "Adaptation" function 10 page 01-135 .
01-135
Adaptation (scan tool function 10)
The following changes can be implemented and

saved using the adaptation function:
Sensitivity settings of the ultra-sound sensors

can be set so that the sensors react with less
sensitivity.
Carrying out "Adaptation" function 10

Select function XX
- Press buttons -1- and -0- to select "Adaptation" function 10.

10 - Adaptation
Adaptation Indicated on display

Insert channel number XX
- Press buttons -0- and -1- to insert channel number 1.
Adaptation Q Indicated on display

Channel display 1
01-136
Channel 1 Adaptation 100 Indicated on display (sensitivity of sensors is displayed: e.g. 100%)
Sensitivity in % - 1 3- Note:
The factory adjusted maximum sensitivity of the ultra-sound sensors is

designated as 100%. The sensor sensitivity can be reduced to 50 %.
- Press button.
Channel 1 Adaptation 100 Indicated on display

- Enter sensitivity value (e.g. 75% = 00075).
Channel 1 Adaptation 100 Q Indicated on display


Sensitivity in % (-1 3-


- Press button to end adaptation procedure for sensitivity.
01-137

05)
Note:

memory again and repair malfunctions.
Requirements
DTC memory checked
All malfunctions repaired
After successfully checking DTC memory:
Carrying out "Erase DTC Memory" function

05

Select function XX
- Press buttons -0- and -5- to select "Erase DTC Memory" function 05.

05 - Erase DTC Memory

DTC memory is now erased.
- Press button.

Select function XX
01-138
Notes:
Attention!
Rapid data transfer

Adhere exactly to the test sequence: first check DTC memory and, if
necessary, repair malfunctions, then erase DTC memory.
After erasing DTC memory carry out function 06 "End Output" then switch
ignition off and on again and check DTC memory again.
01-139
Carrying out "End Output" function 06

Select function XX

06 - End Output

- Disconnect VAG1551 Scan Tool (ST) from Data Link Connector (DLC).
A/C system, electrical testing Page 1 of 47
01-115
A/C system, electrical testing

Notes:
Vehicles 1997 page 01-135 .
VAG1598 test box must not be connected to -

E87- when performing On Board Diagnostic
with VAG1551 Scan Tool (ST)
Test equipment required
VAG1598 test box with adapter cables VAG1598/11, VAG1598/12

and VAG1594 adapter set
Fluke 83 multimeter (US 1119) or equivalent
US 1115 LED tester
Thermometer
Requirements
Battery Positive Voltage (B+) OK
Ground (GND) connections on engine and transmission OK
Fuse No. 42 (S42), 51 (S51), 225 (S225) and 15 (S15) OK
CAUTION!
Switch multimeter to the appropriate measuring range before
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.HA01.01.2 11/21/2002
connecting the test leads to avoid damaging electronic components.
01-116
VAG1598 test box, connecting
- Remove A/C control head -E87- and disconnect

all connectors, -A-, -B-, -C- and -D- page 87-
120 .
- Connect VAG1598/11 and 12 adapter cables to corresponding

connectors of the vehicle wiring harness (to -E87-).
- Connect VAG1598 test box to the respective adapter cable for
performing measurements.
Notes:
Do not connect -E87-.
When using VAG1598/12 adapter cable, the terminal assignment of
the sockets is identical with the terminal assignment of -E87-.
When using VAG1598/11 adapter cable, the terminal assignment of
the sockets is not identical to the terminal assignment of -E87-
terminal assignment, page 01-117 .
01-117
Connector terminal assignment of VAG1598 test box with VAG1598/11 adapter cable
Notes:
The terminal assignment of VAG1598/11adapter cable connectors A and B is not identical to the terminal assignment of
sockets on the VAG1598 test box.
The terminal assignment of VAG1598/11 adapter cable terminal C is identical to the terminal assignment of sockets on the
VAG1598 test box.
The terminal assignment of VAG1598/12 adapter cable terminal D is identical to the terminal assignment of sockets on the
VAG1598 test box
As a result of splitting the connectors to A/C control head -E87- using two adapter cables (VAG1598/11 and 12), no
ground connection exists for the test when VAG1598/11 adapter cable is connected. When performing various electrical
tests, it is therefore necessary to use an external Ground source (vehicle body etc.) or a second VAG1598 test box (when
adapter cable VAG1598/12 is connected, Ground exists at sockets 14 and 15).
01-118
Connector A -E87- VAG1598 Socket E87 Connector B VAG1598 Socket E87 Connector C VAG1598 Socket
1 41 1 21 1 1
2 42 2 22 2 2
3 43 3 23 3 3
4 44 4 24 4 4
5 45 5 25 5 5
6 46 6 26 6 6
7 47 7 27 7 7
8 48 8 28 8 8
9 49 9 29 9 9
10 50 10 30 10 10
11 51 11 31 11 11
12 52 12 32 12 12
13 33 13 13
14 34 14 14
15 35 15 15
16 36 16 16
17 37
18 38
19 39
20 40
01-119
Electrical testing, 1996
Note:
Electrical testing, 1997 page 01-135 .
Test Component(s) tested: Page

number
1 Page 01-
- A/C control head -E87- voltage supply, ground connection and illumination.
120
2 Page 01-
- Temperature sensors G17, G56 and G89
122
3 Page 01-
- Fresh Air Blower V2 and Control module for fresh air blower J126
124
4 Page 01-
- Air/temperature distribution flap motors and related potentiometers V68/-G92-, -V70-/G112,
126
V71/G113 and V85/G114)
5 Page 01-
- A/C compressor speed sender G111
128
- Refrigerant pressure switches -F118- and -F73-
- Interior Temperature Sensor Fan V42
- "A/C compressor intervention" output
- "Excessive engine temperature" signal
6 Page 01-
- A/C Clutch Relay J44
133
- Actuation for coolant fan stage 1
01-120
Test No. 1 (A/C control head -E87- voltage supply, ground connection and illumination)
VAG1598/12 adapter cable Measuring range: Voltage measurement (20 V)

Test VAG1598 Test of Test Specified Corrective action
step socket conditions values
- additional
steps
1.1 9 + 14 Terminal 75x and ground - approx. - Repair voltage supply or ground
Ignition on
connection at -E87- battery voltage connection using wiring diagram.
1.2 9 + 15 Ground connection at -
Ignition on - approx. - Repair ground connection using
E87-
battery voltage wiring diagram.
VAG1598/11 adapter cable Measuring range: Resistance measurement (200 ohm)

- additional
steps
1.3 49 + 52 Ground connection at - less than 20 - Repair ground connection using
-E87- W wiring diagram.
01-121

Test VAG1598 Test of Test Specified values Corrective action
step socket conditions
- additional
steps
1.4 13 and Terminal 30
Ignition off - approx. battery voltage - Repair voltage supply using
ground at E87
wiring diagram.
1.5 7 and Terminal 58 - approx. battery voltage - Repair voltage supply using
Ignition on
ground at E87 wiring diagram.
Parking
lights on
1.6 7 and Terminal 58
Ignition on - less than 2 V - Rectify short circuit to positive
ground at E87 using wiring diagram.
Parking
lights on
1.7 45 and Terminal 58D
Ignition on - 0 to 12 V (depends on - Determine and rectify open circuit
ground at E87
setting of illumination or short circuit using wiring
Parking rheostat) diagram.
lights on
1.8 45 and Terminal 58D
Ignition on - less than 2 V - Rectify short circuit to positive
ground at E87 using wiring diagram.
Parking
lights off
01-122
Test No. 2 (temperature sensors G17, G56 and G89)
VAG1598/11 adapter cable Measuring range: Resistance measurement (20 kohm)

Test VAG1598 Test of Test conditions Specified values Corrective action
step socket
- additional steps
2.1 48 + 52 Outside Air Measure - resistance table, page 01- - Determine and rectify
Temperature temperature at 123 (Resistance values short circuit, open circuit
Sensor G17 mounting location depend on measured in wiring or contact
of sensor temperatures at mounting resistance using wiring
location of sensor(s) diagram.
- Replace applicable
temperature sensor
page 87-106
2.2 50 + 52 Instrument Panel Measure
Interior temperature at
Temperature mounting location
Sensor G56 of sensor
2.3 47 + 52 Fresh Air Intake Measure
Duct Temperature temperature at
Sensor G89
mounting location
of sensor
01-123
Temperature sensor resistances (based on ambient temperature, resistance in k ohm)
Temperature measured at mounting Instrument Panel Outside Air Temperature Sensor -G17- and Fresh Air
location of sensor Interior Intake Duct Temperature Sensor -G89-
Temperature
Sensor
-G56-
-40 C (-40 F) (100) (34.7)
-30 C (-22 F) (52.7) 18.1
-20 C (1 F) (28.6) 9.95
-10 C (14 F) 16.2 5.59
0 C (32 F) 9.40 3.28
5 C (41 F) 7.27 2.54
10 C (50 F) 5.66 1.99
15 C (59 F) 4.45 1.57
20 C (68 F) 3.50 1.25

25 C (77 F) 2.79 1.00
30 C (86 F) 2.23 0.80
35 C (95 F) 1.80 0.65
40 C (104 F) 1.45 0.53
50 C (122 F) 0.79 0.36
60 C (140 F) 0.67 0.25
70 C (158 F) 0.47 -
80 C (176 F) 0.33 -
01-124
Test No. 3 (Fresh Air Blower V2 and Control module for fresh air blower J126)

- additional
steps
3.1 16 and Control module Ignition - Voltage less - Determine and rectify short circuit to positive in
ground for fresh air on than 5 V wiring/connections between J126 and -E87-
blower J126 using wiring diagram.
- Blower does
not run. - Replace J126
3.2 14 and Voltage supply for Ignition - approx. - Repair voltage supply using wiring diagram.
ground Fresh Air Blower on battery
V2 voltage
3.3 11 and Voltage supply for Ignition - approx.

ground J126 (via V2) on battery
voltage
01-125
VAG1598/11 adapter cable

LED voltage tester US 1115
- additional
steps
3.4 13 + 16 Control module for
Ignition - LED in voltage - Determine and rectify open circuit in
fresh air blower -
on tester comes on wiring/connections between -J126- and -
J126-
E87-.
- Fresh air blower
runs - Check Fresh Air Blower V2
operates freely.
- Replace -J126-.
01-126
Test No. 4 (air/temperature distribution flap motors and related potentiometers)
VAG1598/11 adapter cable Measuring range: Resistance measurement (20 kilo ohm)
- additional
steps
4.1 52 + Potentiometer
- greater than 0.1kW and less - Determine and rectify open circuit
(in flap motor) than 5.7kW (depends on in wiring, contact resistance or short
28 -G92- (-V68-)
position of flap motor) circuit using wiring diagram.
29 -G112- (-V70-
37 ) - Replace applicable flap motor
30 -G113- (-V71- page 87-106 .
)
-G114- (-V85-
)
4.2 8+ Potentiometer - greater than 0.1kW and less
(in flap motor) than 5.7kW (depends on
28 -G92- (-V68-) position of flap motor)
29 -G112- (-V70-
37 )
30 -G113- (-V71-
)
-G114- (-V85-
)
Notes:
Potentiometer resistance (Specified values: 3.6 k to 5.7 k between flap motor terminal 3 and 4) can only be measured
directly at the flap motor (parallel circuit).
Potentiometers resistance (between flap motor terminal 3 and 5, plus 4 and 5) depends on the position of the flap motor.
Measure only with installed flap motor. The upper specified value is not achieved in test steps 4.1 and 4.2 (to achieve this
value, all connectors of the other flap motors would have to be unplugged during the measurement, parallel circuit).
If -E87- recognizes DTC" potentiometer short circuit to ground or open circuit/short circuit to positive", test all
potentiometers.
01-127

- additional
steps
4.3 2 + 10 Temperature Regulator 20 W to 100 - Determine and rectify open circuit in
Flap Motor -V68- W wiring, contact resistance or short circuit
using wiring diagram.
- Replace applicable flap motor page
87-106 .
4.4 4 + 12 Central Flap Motor -V70- 20 W to 100
W
4.5 5 + 13 Air Flow Flap Motor -V71- 20 W to 100
W
4.6 3 + 11 Footwell/Defroster Flap 20 W to 100
Motor -V85- W
01-128
Test No. 5 (A/C Compressor Speed Sensor -G111-, refrigerant pressure switches -F118-, -F73- and Interior
Temperature Sensor Fan -V42-)
Note:
Electrical test steps 5.1 to 5.4 do not apply to vehicles equipped with Nippondenso compressors (A/C compressor speed
sensor G111 is not installed on Nippondenso compressors).
VAG1598/11 adapter cable Measuring range: Resistance measurement (20 kilo ohm)
- additional
steps
5.1 5 + 49 A/C Compressor - 0.8 kW to - Determine and rectify open circuit in
Speed Sender -G111- 1.5 kW wiring, contact resistance or short circuit
using wiring diagram.
- Replace -G111- page 87-63 .
5.2 5 and A/C Compressor - greater - Determine and rectify short circuit using
ground Speed Sender -G111- than wiring diagram.
2 kW
- Replace -G111- page 87-63 .
01-129

Test VAG1598 Test of Test conditions Specified Corrective action
step socket values
- additional steps
5.3 5 and A/C Compressor Speed
Engine running - less than 1 - Determine and rectify short
ground Sender -G111- V circuit using wiring diagram.
Compressor not
running
Note: additional test steps before proceeding with this test.

Test VAG1598 Test of Test conditions Specified values Corrective
step socket action
- additional steps
5.4 5 and A/C Compressor
Engine running - greater than 0.05 V - Replace -G111-
ground Speed Sender - (depends on engine page 87-63 .
G111- Compressor running speed)
- Relay for A/C Clutch removed
- Bridge terminals 30 + 87 at relay
connector base (A/C Clutch
switched on)
01-130

- additional
steps
5.5 2 + 49 A/C Refrigerant High - less than - Determine and rectify open circuit in
Pressure Switch -F118- 20 W wiring or contact resistance using wiring
diagram.1)
- Replace -F118- page 87-25 .
1)If code 1 "high-pressure switch -F118 open" is displayed in measuring value block 1 as a compressor cut-off condition: -Test
connections to -F118- for loose terminal using wiring diagram. -Test actuation of Coolant Fan V7 stage 1 Output Diagnostic
Test Mode, page 01-42 . Test actuation of Coolant Fan V7 stage 2 page 01-42 . If no fault can be determined, check for
refrigerant system malfunction, refrigerant system pressure test page 87-190 .
01-131

- additional
steps
5.6 3 + ground A/C Refrigerant Low
Ignition on - approx. - Determine and rectify open circuit in
Pressure Switch -F73-
battery voltage voltage supply using wiring diagram.
- -F73- malfunction page 87-66
- Refrigerant circuit empty, refrigerant
system pressure test page 87-190
VAG1598/11 adapter cable Measuring range: Amperage (20 amps (A))

- additional
steps
5.7 44 + Interior Ignition - less than - Determine and rectify open circuit, short circuit to
ground Temperature on 1A positive/ground in the wiring/connections between
Sensor Fan -V42- V42 and -E87- using wiring diagram.
- Blower
V42 runs
01-132

LED voltage tester US 1115
- additional
steps
5.8 13 + 12 "AC compressor
Engine - LED in voltage - Determine and rectify short
intervention" output
running tester does not come circuit to ground using wiring
on diagram.
- Rectify cut-off condition for A/C
compressor in ECM.
compressor in TCM -J217-.
5.9 13 + 51 "Engine temperature Engine - LED in voltage - Determine and rectify short
too high" signal running tester does not come circuit to ground using wiring
on diagram.
compressor in Instrument Cluster.
01-133
Test No. 6 (A/C Clutch Relay J44, actuation of Coolant Fan V7 stage 1)

- additional
steps
6.1 8 + 14 A/C Clutch Engine - less than 1 A - Determine and rectify open circuit or short circuit to
Relay - running positive in wiring/connections between A/C Clutch -
J44- - Compressor N25-, -J44- and -E87- using wiring diagram.
engaged and
running. - A/C Refrigerant Low Pressure Switch -F73- open,
test page 01-131
- Replace -J44-.
- Repair or replace A/C Clutch -N25- page 87-85 .
01-134

- additional
steps
6.2 16 + 14 Control of Coolant Fan Engine - less than - Determine and rectify open circuit or short
control (FC) relay -J26- (for running 1A circuit to positive in wiring/connections
stage 1 operation of between -J26- and -E87- using wiring
Coolant Fan -V7-) - Fan runs diagram.
in stage 1.
- Check -V7- Repair Group 19
Note:
Testing operation of coolant fan via refrigerant high pressure switch F23 page 87-64 .
01-135
Electrical testing, 1997
Note:
Electrical testing, 1996 page 01-119 .
Notes:
VAG1598 test box must not be connected to A/C control head -E87- when performing On Board Diagnostic with VAG1551
Scan Tool (ST)
Further notes, test requirements, connecting adapter cables and test equipment page 01-115 .
From m.y. 1997, do not connect VAG1598 test box to -E87- for test steps 1.1 through 5.7. (Test box only to be connected
for test steps 5.8, 5.9 and 5.10).
Test Component(s) tested: Page

number
1 Page 01-
- A/C control head -E87-, voltage supply and ground connection
136
- Signal for time span ignition off
2 Page 01-
- Temperature sensors -G17-, G56, -G89- -G191- and -G192-
138
3 Page 01-
- Fresh air blower -V2-, Control module for fresh air blower -J126-
140
4 Page 01-
- Air/temperature distribution flap motors and related potentiometers (-V68-/-G92-, -V70-/-
141
G112-, -V71-/-G113-, -V85-/-G114-)
5 Page 01-
- A/C pressure switch -F129-
142
- "A/C compressor intervention" output
- "Excessive engine temperature" signal
- Interior temperature sensor fan -V42-
6 Page 01-
- A/C clutch relay -J44-, A/C clutch -N25-, actuation
146
- Coolant fan -V7-, actuation
01-136
Test No. 1 (A/C control head -E87- voltage supply, ground connection)
Adapter cable VAG1598/12
Measuring range: Voltage measurement (20 V)

Test VAG1598 Test of Test Specified value Corrective action
Step socket conditions
- additional
steps
1.1 9 + 14 Terminal 15 and ground
Ignition on - approx. - Repair voltage supply or ground
connection at -E87- battery voltage. connection using wiring diagram.
1.2 9 + 15 terminal 15 and ground
Ignition on - approx. - Repair ground connection using
connection at -E87- battery voltage. wiring diagram.
1.3 page 01-120
1.4 Not for 1997. Terminal 30 no longer connected
1.5 to These test steps are conducted only for vehicles up to and including m.y. 1997 (A/C control head with Part. No.
1.8 8D0 820 043 and Part No. 8L0 820 043 up to Part No. index letter "C").
01-137
LED Voltage tester VAG1527B

Test VAG1598 Test of Test Specified Value Corrective action
Step socket conditions
- additional
work
1.9 term.15 1) + Signal for time
Ignition - LED lights up - Diagnose and repair short or open
33 span ignition on circuit in wiring/connections using wiring
off diagram.
1.10 term.15 1) + Signal for time Ignition - LED lights up - Diagnose and repair short or open
33 span ignition on circuit in wiring/connections using wiring
off diagram.
- Check signal from instrument cluster.
- LED flickers briefly
- Start (time signal) and then
engine. lights up again
1) Terminal 15 (ignition) is available at -E87- connector -D-, terminal -9-.
01-138
Test No. 2 (Temperature Sensors -G17-, -G56-, -G89-, G191-, G192-. )
Measuring range: Resistance measurement (20 K / 200 K )

Test VAG1598 Test of Test conditions Specified Value Corrective action
Step socket
- additional work
2.1 to page 01-122
2.3
2.4 26 + 49 Sender for outlet - Measure - Dependant on temperature - Diagnose and repair short,
temperature, temperature at at mounting location of open circuit or contact
center -G191-. mounting location sensor resistance in
of sensor. wiring/connections using
wiring diagram.
2.5 25 + 49 Sender for outlet - Measure Confirm using
- Replace sensor(s)
temperature, floor temperature at temperature/resistance
outlet -G192-. table page 01-139
mounting location
of sensor.
01-139
Temperature sensor resistances (based on ambient temperature, resistance in k ohm)
Temperature measured at mounting Sender for outlet temperature, Sender for outlet temperature, floor
location of sensor center -G191- outlet -G192-
-30 C (-22 F) (141) (52,7)
-20 C (1 F) (85) (28,6)
-10 C (14 F) (47) 16,2
0 C (32 F) (29) 9,40
5 C (41 F) (23,2) 7,27

10 C (50 F) 18,6 5.66
15 C (59 F) 15 4,45
20 C (68 F) 12,2 3,50
25 C (77 F) 10 2,79
30 C (86 F) 8,2 2,23
35 C (95 F) 6,8 1,80
40 C (104 F) 5,7 1,45
50 C (122 F) 4,0 0,97
60 C (140 F) 2,9 0,67
70 C (158 F) 2,1 0,47
01-140
Test No. 3 (Fresh Air Blower -V2- and Control Module for Fresh Air Blower -J126-)

Test Step VAG1598 socket Test of Test conditions Specified Value Corrective action
- additional work
3.1 to 3.3 page 01-124

step socket conditions Value
- additional
work
3.4 14 + 16 Control module for Ignition - LED lights up - Diagnose and repair open circuit in
fresh air blower - on wiring between -J126- and -E87- using
J126- wiring diagram.
- Fresh Air Blower -V2- check for ease of
movement.
- Fresh air - Replace -J126-.

blower running.
01-141
Test No. 4 (air/temperature distribution flap motors and related potentiometers)
Measuring range: Resistance measurement (20 K )

Step socket conditions Value
- additional
work
4.1 to page 01-126
4.6
4.7 14 + Short to ground of wiring to Ignition - Ohm - Diagnose and repair short to ground in
2 flap motors -V68-, -V85-, - off wiring/connections using wiring diagram.
3 V70-, -V71-
4
5

- additional
work
4.8 14 + 2 Short to positive of wiring to Ignition - less than - Diagnose and repair short to positive
3 flap motors -V68-, -V85-, - on 1V in wiring/connections using wiring
4 V70-, -V71- diagram.

5
Note:
If DTC's for several flap motors are shown and malfunction is not determined in test 4, check wiring for short between
individual flap motors (e.g. -V85- and -V70-, measured value between sockets 3 and 4 must be Ohm).
01-142
Test No. 5 (A/C pressure switch -F129-, "A/C compressor intervention" signal, engine temperature signal from
instrument cluster and Interior Temperature Sensor Fan -V42-)
Measuring range: Resistance measurement (200 )

Test VAG1598 socket Test of Test conditions Specified Value Corrective action
Step
- additional work
5.1 to Not for 1997. A/C compressor speed sender -G111-, A/C high pressure switch -F118- and Low pressure switch -
5.6 F73- are no longer installed
Measuring range: Current measurement (20 A)

- additional work
5.7 page 01-131
01-143
A/C control head -E87- connected to test box with adapter cable VAG1598/11

Step socket Value
- additional work
5.8 14 + 12 "A/C compressor
Engine - LED lights - Diagnose and repair open or short circuit in
intervention"
running. up wiring/connections using wiring diagram.
output.
A/C - Diagnose and eliminate A/C compressor
compressor cut-off condition(s) from Engine Control
off - LED lights Module (ECM) or Transmission Control
up slightly Module (TCM)
- Switch on A/C dimmer.
compressor - Diagnose and repair short circuit to ground
in wiring/connections using wiring diagram.
5.9 Ground "Engine Engine - LED lights - Diagnose and repair short circuit to ground
and temperature too running. up. in wiring/connections using wiring diagram.
51 high" signal.
- Diagnose and eliminate A/C compressor
cut-off condition from Instrument cluster
01-144
A/C control head -E87- connected to test box with adapter cable VAG1598/11
Measuring range: Current measurement (200 mA)

Step socket Value
- additional work
5.10 Ground "A/C compressor
Engine running. - Less than 5 - Diagnose and repair short circuit to
and intervention"
mA positive in wiring/connections using
12 output. A/C compressor wiring diagram.
off
- Replace A/C control head -E87-.
- Switch on A/C - Less than

compressor 50 mA
- Compressor - Diagnose and eliminate A/C
does not en- compressor cut-off condition(s) from
gage Engine Control Module (ECM) or
- Remove multimeter Transmission Control Module (TCM)
connector probes - Compressor
from test box engages
Repair Manual, Fuel Injection and
Ignition
Repair Manual, Automatic

Transmission
- Diagnose and repair short circuit to

ground in wiring/connections using
wiring diagram.
01-145
Adapter cable VAG1598/11 connected.
Measuring range: Resistance measurement (200 )

- additional
work
5.11 2 + 42 A/C pressure switch -
Ignition - Less than - Diagnose and repair open circuit or contact
F129- (between
off 20 resistance in wiring/connections using wiring
terminals 1 and 2) diagram.1).
- Check A/C pressure switch -F129- page
87-67 .
1)If compressor cut-off condition code 1, "A/C pressure switch -F129- open" etc. appears in read measuring value block,
display group 1, display field 1: - check for intermittent contact in wiring/connections to -F129- using wiring diagram - check
function of Coolant Fan -V7- stage 1 with Output DTM (function 03) page 01-42 - check A/C pressure switch -F129- function
(actuation of -V7- stage 2, terminals 3 and 4 page 87-67 ). If no fault is determined, check A/C refrigerant system pressures
page 87-190 .
01-146
Test No. 6 (A/C Clutch Relay -J44-, actuation of Coolant Fan -V7- stage 1)
Adapter cable VAG1598/12 connected.
Measuring range: Amperage measurement (20 A)

- additional work
6.1 + 6.2 page 01-133
Note:
Actuation of -V7- stage 2 via A/C pressure switch -F129- page 87-67 .
01-147
Notes:
The following test steps are only performed for A/C control heads -E87- with two displays:
Teststep 2.2 (the instrument panel interior temperature sensor -G56- is installed in A/C control heads -E87- with one
display)
Test step 5.7 (the interior temperature sensor fan -V42- is installed in A/C control heads -E87- with one display)
Switch on test area at VAG1526 multimeter: voltage test (20 V =)
VAG1598/11 adapter cable connected
Test VAG1598A Test of Test Specified Corrective action

step socket requirements value
- additional
operations
1.15 46 + Ground Power supply Ignition - Locate and repair open circuit or short
4) 3) terminal 58 of A/C switched on circuit to Ground in wiring connection to
control head -E87- A/C control head -E87- using wiring
Park light diagram
switched on approx.
battery
voltage
1.16 46 + Ground Power supply Ignition - Locate and repair open circuit or short
4) 3) terminal 58 of A/C switched on circuit to Ground in wiring connection to
control head -E87- A/C control head -E87- using wiring
Park light diagram.
switched off smaller

than 2 V
3) Ground is at, for example, connector D, socket 14 and 15.
4) Only perform this test step for an A/C control head with one display.
01-148
Switch on test area at VAG1526 multimeter: voltage test (20 V)
Test VAG1598A Test of Test Specified Corrective action

step socket requirements value
- additional
operations
1.17 8 Terminal 15 and Ground Ignition approx. - Repair power supply or
4) connection at A/C control head switched on battery Ground connection
+ -E87- (power supply for A/C voltage according to wiring
clutch) diagram
14
4) Only perform this test step for an A/C control head with one display.
01-149
VAG1527 B Voltage Tester
A/C control head -E87- connected at test box (VAG1598/11 and /12 adapter cables)
Test VAG1598A Test of Test Specified value Corrective action

step socket requirements
- additional
operations
5.9 5) Ground "Engine temperature Engine LED on - Locate short circuit to Ground
too high" signal running voltage tester and repair according wiring
+ lights diagram
51 - Eliminate A/C compressor cut-
off conditions in instrument
cluster
5) Only perform this test step for vehicles of m.y. 1997 or later
Notes:
Ignition key coding is transmitted to the A/C control head -E87- from the instrument cluster along with the coolant
temperature and the signal "engine temperature too high" when ignition is switched on for vehicles as of m.y. 1999 (data
message). Key coding can only be processed by A/C control heads -E87- with part number 8D0 820 043 after index "M."
No information can be transmitted if the coolant temperature is too high.
When ignition is switched on, A/C control head -E87- begins with the setting that was valid when the ignition was last
switched off with this key (temperature, air distribution, fresh air blower RPM).
The signal from instrument cluster (data message) cannot be checked with tools available.
Repair Manual, "Electrical Equipment," Repair Group 90, instrument cluster, repairing.
01-150
List of changes to electrical tests, 1998
VAG1527B voltage tester

step conditions
sockets value
- additional
operations
1.9 33 + Signal for LED on voltage tester lights
Ignition - Repair open circuit or
GND "ignition off" switched on short circuit according to
period wiring diagram.
1.10 33 + Signal for LED in voltage tester lights up
Ignition - Repair open circuit or
GND "ignition off" switched on short circuit according to
period When starting engine, LED briefly wiring diagram.
- Start engine. flickers in voltage tester (time signal)
and then lights constantly - Check instrument cluster.
Note:
Test steps 1.9 and 1.10 apply only for vehicles beginning m.y. 1997 (A/C control head with Part No. 8L0 820 043 up to Part
No. index letter "C").
01-151
Voltage test - switch multimeter to 20V measuring range

step
sockets - additional value
operations
1.11 7 + GND Terminal 58s on - 0 to 12 V
Ignition switched - Repair open circuit or short circuit
E87- on according to wiring diagram.
Parking light
switched on
1.12 7+ GND Terminal 58s on - Ignition switched approx. 0 - Repair short to B+ according to wiring
E87- on V. diagram.
Parking light
switched off
Notes:
Test steps 1.11 to 1.14 apply for vehicles beginning m.y. 1998 (A/C control head with Part No. 8L0 820 043 from Part No.
index letter "D").
The Ground connection can be made via connector D, terminals 14 and 15 (for example).
The voltage at terminal 58s is dependent on the adjustment of the illumination dimmer control.
01-152
Voltage test - switch multimeter to 20V measuring range

step
sockets - additional value
operations
1.13 45 + Terminal 58d on - 0 to12 V
Ignition switched - Repair open circuit or short circuit
GND E87- on according to wiring diagram.
Parking light
switched on
1.14 45 + Terminal 58d on - Ignition switched 0 to 12 V - Repair open circuit or short circuit
GND E87- on according to wiring diagram.
Parking light
switched off
Notes:
Test steps 1.11 - 1.14 apply for vehicles beginning m.y. 1998 (A/C control head with Part No 8L0 820 043 from Part No.
index letter "D").
The Ground connection can be made via connector D, terminals 14 and 15 (for example).
The voltage to terminal 58d is created as a square-wave signal from the instrument cluster. The brightness of the display
on A/C control head -E87- is determined by the period of activation. The multimeter will indicate the average value.
The period of activation for terminal 58d is dependent on the setting of the illumination dimmer control and on the
brightness level detected by the photo sensor in the instrument cluster.
ABS/EDL/ASR Bosch 5.3 Page 1 of 11
01-120
ABS/EDL/ASR Bosch 5.3

Warning light, functional overview
If On Board Diagnostic (OBD) has detected a

malfunction in the system, it indicates the
malfunction by lighting up warning lamps when
ignition is switched on. The warning lamps are
located in the instrument cluster.
Instrument cluster without DIS
The illustration shows the ABS/EDL warning light -K47- (right arrow),
the warning light for brake system -K118- (center arrow, red symbol
for "brake system malfunction") and the traction control indicator light -
K86- (left arrow).
Instrument cluster with DIS
For DIS, there is no warning light for brake system -K118-. The red
"brake system malfunction" symbol appears in the display.
If the ABS/EDL warning light -K47 and the red symbol for "Brake
system malfunction" are not lit, but the brake system is not functioning
properly, check for malfunctions in the mechanical/hydraulic brake
system components.
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.SU02.01.9 11/20/2002
Repair manual, Brake System, Repair Group 46
01-121
ABS/EDL Brake ASR Reasons why the indicator lamps light up

system
-K47-
-
K86-
1)
If an irregularity occurs during the self test after ignition is switched on, and the
warning lamps -K47- and -K86- do not light up for 2 seconds, check the warning lamps;
"Electrical test" page 01-166 , carry out test steps 8 and 10. The possible causes are
as follows:
The battery voltage is insufficient. None of the lamps in the instrument cluster light up.
Check the battery.
Repair Manual, Electrical Equipment, Repair Group 27, Battery
The ABS/EDL warning light does not light up during the self-test. There is a short to
Ground (GND) in the wiring that controls the ABS/EDL warning light between terminal 21
of the ABS control module -J104- and the instrument cluster. This malfunction does not
affect activation of the ABS warning light. For vehicles equipped with ASR, the traction
control indicator lamp lights up during the self-test; "Electrical test" page 01-166 , carry
out test step 8.
X 1)
The vehicle is equipped with ASR. The ABS/EDL warning light lights up during the self-
test. The traction control indicator light does not light up during the self-test "Electrical
X test" page 01-166 , carry out test step 10.
1) The traction control indicator light is only available in vehicles equipped with ASR.
01-122

system
-K47-
-
K86-
1)
For all vehicles:
If activation of both the ABS warning light -K47- and traction control indicator light -K86- is
OK and the voltage supply is OK, the warning lamps light up for 2 seconds during the self-
test after ignition is switched on.
Check the voltage supply for the red "brake system malfunction" symbol. Carry out
"Electrical test" step 9, page 01-166 . If the control is malfunctioning, see the next
example for lighted indicator lights.
For DTCs stored in DTC memory that are no longer detected during the self-test when
ignition is switched on or when a specific vehicle speed is reached and are found to be OK
when checked, the red "brake system malfunction" symbol does not light up. For
example:If there was a dynamic malfunction of the wheel speed sensor during the last
driving period, the warning lamps automatically switch off after vehicle is restarted if wheel
speed sensor is tested as OK once a vehicle speed of 2.75 km/h is reached.
For vehicles with control modules that do not provide EBD emergency mode:
- These vehicles can be identified by checking the note column under "Check control module
version"; page 01-128 .
X X1)
Voltage supply for the ABS control module -J104- is between 7 and 10 volts and the
vehicle speed is 12 km/h. If the vehicle speed exceeds 6 km/h, a DTC entry will be
made in DTC memory. At a vehicle speed of > 12 km/h, the red "brake system
malfunction" symbol lights up; "Check DTC memory" page 01-187
01-123
ABS/EDL Brake ASR Possible reasons why the indicator lamps light up
system
-K47-
-
K86-
1)
For vehicles with control modules that provide EBD emergency mode:
- These vehicles can be identified by checking the note column under "Check control module
version"; page 01-128 .
A DTC is stored in the DTC memory the first time the vehicle exceeds 6 km/h, if the
voltage supply to the ABS control module -J104- is between 7 and 10 volts and the
indicator lights go on. If the voltage supply of the ABS control module -J104- exceeds 10
volts while driving, the indicator lights switch off. The DTC remains in the memory. If the
voltage supply value drops below 10 volts again during the same driving cycle, the
indicator lamps light up again. "Check DTC memory" page 01-187
The indicator lights do not switch off after the self-test. However, the red "brake system
X X1) malfunction" symbol did not go on. On Board Diagnostic (OBD) recognized a malfunction
that did not deactivate the Electronic Brake Distribution (EBD) system. "Check DTC
memory" page 01-187
01-124

system
-K47-
-
K86-
1)
The vehicle can be equipped either with or without ASR. The ABS/EDL lamp remains
constantly lit after ignition is switched on and the the red "brake system malfunction" symbol
also lights up 3 seconds after ignition is switched on.
WARNING!
Driving the vehicle presents the risk of accident! The brake system will only be partially
functional. Because brake pressure at the rear wheels is no longer regulated vie
Electronic Brake Distribution (EBD), the rear wheels tend to brake excessively. This
causes the rear of the vehicle to break loose.
For all vehicles:
The VAG1551 Scan Tool (ST) is connected and the data link to the ABS control module
(w/EDL) -J104- was established. For vehicles with automatic transmission and high-line
instrument cluster, the red "brake system malfunction" symbol does not appear
immediately after the ignition is switched on. Instead, the note "Depress brake pedal
before engaging gear" appears in the display. Press the brake pedal and select a gear.
X X X1) The red brake warning light appears, if the light control is working properly.
On Board Diagnostic (OBD) recognized a malfunction that led to deactivation of Electronic
Brake Distribution (EBD), ABS, EDL or ASR. "Check DTC memory" page 01-187
01-125
ABS/EDL Brake ASR Possible reasons why the indicator lamps light up
system
-K47- -K86-
1)
Additional information for vehicles with control modules that do not provide EBD
emergency mode:
- These vehicles can be identified by checking the note column under "Check control
module version"; page 01-128 .
Voltage supply for the ABS control module -J104- is between 7 and 10 volts and the
vehicle speed is > 12 km/h. A DTC will be entered in DTC memory once vehicle reaches
a speed > 6 km/h. "Check DTC memory" page 01-187
X X X1)
01-126

system
-K47-
-K86-
1)
The vehicle is equipped with ASR:
There is a malfunction that affects only the ASR system. The ABS and EDL systems are
not deactivated. Check DTC memory page 01-187
ASR is switched off via the traction control button. If the traction control indicator light
does not light up in this case, check the switch and the indicator light, carry out the
"Electrical test", steps 10 and 11 page 01-166 .
ASR is in adjustment mode. The traction control indicator light blinks 3 times per second.
Short circuit to B+ in the traction control button: The traction control indicator light
switches off five minutes after ignition is switched on.
X1) The lamp remains constantly lit after ignition is switched on, but none of the above
mentioned conditions are true. There is a short to Ground (GND) in the wiring that
controls the traction control indicator light between terminal 20 of the ABS control module
-J104- and the instrument cluster.
There is an irregularity present or a complaint has been made. The indicator lamps go
on during the self-test and then go out. The possible causes are as follows:
The DTC "Brake light switch -F-" is stored in DTC memory , check DTC memory page
01-187 .
The DTC "ABS/instrument cluster electrical connection" is stored in DTC memory , check
DTC memory page 01-187 .
The onset of EDL was shut-off to avoid an overheating in the brake system, read
measuring value block page 01-140 .
01-127

system
-K47-
-
K86-
1)
The vehicle can be equipped either with or without ASR. No DTCs are stored in DTC
memory. The ABS/EDL lamp remains constantly lit after ignition is switched on and the
the red "brake system malfunction" symbol also lights up 3 seconds after ignition is
switched on. The traction control indicator lamp does not light up even for vehicles
equipped with ASR.
There is an open circuit or short circuit to B+ in the wire that controls the ABS/EDL
warning lamp between terminal 21 of the ABS control module -J104- and the instrument
cluster; carry out "Electrical test" step 8 page 01-166 .
Voltage supply for control module less than 6 volts; carry out "Electrical test" step 1
X X
page 01-166 .
No DTCs are stored in DTC memory. The red "brake system malfunction" symbol
remains lit after the ignition is switched on.
X
The brake fluid level is too low.
Malfunction in instrument cluster: Carry out "Electrical test" step 9, page 01-166 .
Page 1 of 8
01-128
Check Control Module Version

(function 01)
- Connect the VAG1551 Scan Tool (ST) and
select address word 03 "Brake Electronics".
- Advance through program sequence by pressing

the button.

Select function XX
- Press buttons -0- and -1- to select "Check Control Module Version" 01.
Press -Q- button to confirm input.
Notes:
The control module version can only be changed by replacing the
control module.
Allocation of the ABS control module -J104-, see also parts catalog.
file://C:\DOCUME~1\Bear\LOCALS~1\Temp\triGJIEM.htm 11/20/2002
Page 2 of 8
01-129
8E0 614 111 1) 2) 3) Indicated on display:

Coding 00000 WSCXXXXX
The coding is only indicated for vehicles with Anti-Slip Regulation (ASR),
coding control module page 01-135 .
The workshop code, WSC XXXXX, indicates the workshop where the
control module was last coded.
IndeX 1): Indicates control module index.
Index 2): Indicates system identification.
Index 3): Indicates hardware and software status
- Press button.

Select function XX
Page 3 of 8
01-130
ABS control module versions without CAN bus
System Prod. Control Index Coding Data Notes:

identification No.: 1) module transmission
part no.: via:
Front Wheel Drive 1AC 8E0 614 - coding not single wires Not pre-bled hydraulic control unit for
(FWD)/ABS Bosch 111 possible production.
5.3
8E0 614 AB coding not single wires Not pre-bled hydraulic control unit for
111 possible production. With EBD emergency mode.
8E0 614 AD coding not single wires Not pre-bled hydraulic control unit for
111 possible production. With EBD emergency mode
and wheel speed sensor outputs at rear
left and rear right for navigation.
8E0 614 D coding not single wires Pre-bled hydraulic control unit for
111 possible customer service.
8E0 614 AC coding not single wires Pre-bled hydraulic control unit for
111 possible customer service. With EBD emergency
mode.
8E0 614 AE coding not single wires Pre-bled hydraulic control unit for
111 possible customer service. With EBD emergency
mode and wheel speed sensor outputs
at rear left and rear right for navigation.
1)This letter code is the production number allocated to each equipment version. The production number can be derived from
the vehicle data plate. The vehicle data plate is attached to the vehicle in the spare tire well.
Page 4 of 8
01-131
ABS, EDL control module versions without CAN bus
System identification Prod. Control Index Coding Data Notes:

No.: 1) module transmission
part no.: via:
Front Wheel Drive 1AH 8E0 614 P coding not single wires Unbled hydraulic control unit for
(FWD)/ABS/EDL Bosch 111 possible production.
5.3
8E0 614 B coding not single wires Unbled hydraulic control unit for
111 possible production. With integrated suction
damper and EBD emergency
mode.
8E0 614 Q coding not single wires Pre-bled hydraulic control unit for
8E0 614 F coding not single wires Pre-bled hydraulic control unit for
111 possible customer service. With integrated
suction damper and EBD
emergency mode.
Page 5 of 8
01-132

part no.: via:
All Wheel Drive 1AH 8E0 614 M coding not single wires Unbled hydraulic control unit for
(AWD)/ABS/EDL 111 possible production.
Bosch 5.3
8E0 614 A coding not single wires Unbled hydraulic control unit for
111 possible production. With integrated suction
damper and EBD emergency
mode.
8E0 614 N coding not single wires Pre-bled hydraulic control unit for
8E0 614 E coding not single wires Pre-bled hydraulic control unit for
suction damper and EBD
emergency mode.
Page 6 of 8
01-133
ASR control module versions Bosch 5.3 without CAN bus

part no.: via:
Front Wheel Drive 1AJ 8E0 614 R coding single wires Unbled hydraulic control unit for
(FWD)/ABS/ASR 111 possible production.
Bosch 5.3 page 01-135
8E0 614 C coding single wires Unbled hydraulic control unit for
111 possible production. With integrated
page 01-135 suction damper and EBD
emergency mode.
8E0 614 S coding single wires Pre-bled hydraulic control unit for
page 01-135
8E0 614 G coding single wires Pre-bled hydraulic control unit for
emergency mode.
Page 7 of 8
01-134
ASR control module versions Bosch 5.3 with CAN bus

part no.: via:
Front Wheel Drive 1AJ 4D0 H coding not CAN-bus Unbled hydraulic control unit for
(FWD)/ABS/ASR 614,111 possible production.
Bosch 5.3
4D0 J coding not CAN-bus Pre-bled hydraulic control unit for
614,111 possible customer service.
8E0 614 H coding CAN-bus Unbled hydraulic control unit for
111 possible production. With integrated
emergency mode.
8E0 614 J coding CAN-bus Pre-bled hydraulic control unit for
emergency mode.
8E0 614 AH Can be CAN-bus 120
111 coded
8E0 614 AJ Can be CAN-bus 120
111 coded
8E0 614 AQ Can be CAN-bus 1120
111 coded
3B0 614 Can be CAN-bus 1120
111 coded
Page 8 of 8
01-135
Code Control Module

(function 07)
Has an ASR control module just been replaced
or is one of the following DTCs stored in DTC
memory of the control module?
"ABS/EDL transmission electrical connection"
"Control module incorrectly coded"
"CAN-bus missing signal from Transmission

Control Module (TCM)"
If so, control module must be coded according to

engine and transmission type.
Notes:
Coding is only possible if a workshop number is

stored in the VAG1551 Scan Tool (ST).
Operating instructions for VAG1551
During control module identification the 5-digit

code will be indicated.
01-136

- Check the control module version page 01-

128 and press the button.
- Press button.

Select function XX
- Press buttons -0- and -7- to select "Code control module" function 03.

07 - Code control module

Enter code number XXXXX
- Enter the appropriate code number and press -Q- button to confirm
input.
01-137
Coding table ABS/EDL/ASR with CAN
Engine Transmission Data transmission Control module part number Code

via: with index number
1.8 T1) 4 5V Manual 01E CAN-bus 8E0 614 111 AH; AJ;AQ 00022
Cyl. transmission
Automatic 01V CAN-bus 8E0 614 111 AH; AJ;AQ 00021
transmission
2.4 Liter 6 5V Manual 01E CAN-bus 8E0 614 111 AH; AJ;AQ 00032
Cyl. transmission
2.7 Liter 5V
6
2.8 Liter Cyl. 5V
6
Cyl.
2.4 Liter 6 5V Automatic 01V CAN-bus 8E0 614 111 AH; AJ; AQ 00031
Cyl. transmission
2.7 Liter 5V
6
2.8 Liter Cyl. 5V
6
Cyl.
2.5 Liter 6 4V TDI Manual 01E CAN-bus 8E0 614 111 AH; AJ; AQ 00012
Cyl. transmission
1.9 TDI H; J;
PD2) 4 4V
Cyl.
2.5 Liter 6 4V TDI Automatic 01V CAN-bus 8E0 614 111 AH; AJ; AQ 00011
Cyl. transmission
1.9 TDI H; J;
PD2) 4 4V
Cyl.
1) 1.8 T means 1.8 Liter Turbo engine
2) 1.9 PD means 1.9 Liter injection Pump Diesel engine
01-138
Engine Transmission Data Control module Code Note:

transmission part number number
via: with index
2.4 6 5V Manual 012 single wires 8E0 614 R; 00000 Terminal 28 at ABS
Liter Cyl. transmission 111 S control module (w/EDL) -
J104- not occupied.
C;
G
Automatic 01V single wires 8E0 614 R; 00003 Terminal 28 at ABS
transmission 111 S control module (w/EDL) -
J104- occupied with 12V.
C;
G
2.8 6 5V Manual 012 single wires 8E0 614 R; 00000 Terminal 28 at ABS
Liter Cyl. transmission 111 S control module (w/EDL) -
J104- not occupied.
C;
G
Automatic 01V single wires 8E0 614 R; 00003 Terminal 28 at ABS
transmission 111 S control module (w/EDL) -
J104- occupied with 12V.
C;
G
01-139
4D0 907 379 X Syst. ident. Software ver. Display will indicate the control module identification and the coding
Coding 00000 WSCXXXXX entered (e.g. 00000).
- Press button.

Select function XX
- Press buttons -0- and -6- to select "End Output" function 06. Press -Q-
01-140

(function 08)
The control module can transmit measured
values. These measured values provide
information about the operational status of the
system and the sensors connected to it. In many
cases the data supplied can be used to
troubleshoot and repair malfunctions. The
measured values from the ABS/EDL Bosch 5.3
series are contained in four display groups,
which can be accessed via their display group
numbers.
- Observe safety precautions that apply to road

tests.

Notes:
When the printer is switched on, the contents of

the display will be printed out on the scan tool
log.
When reading the measuring value block, also

check wiring and connectors for loose
terminals.

01-141

Select function XX
- Press buttons -0- and -8- to select "Read measuring value block"
function 08.

08 - Read measuring value block
Read measuring value block HELP Indicated on display:

- Press buttons -0-, -0- and -1-.
01-142
Test table: display group 1
Notes:
Display fields 1 through 4 show the current wheel circumference speeds in km/h. These are calculated by the ABS control
module -J104- on the basis of the signals received from the wheel speed sensors. If one of the display fields shows no
reading, proceed as for DTCs 00283, 00285, 00287, 00290 "ABS Wheel Speed Sensor" Diagnostic Trouble Code (DTC)
table
In order to check whether wheel speed sensors are properly allocated to each wheel, the vehicle must be raised. On
vehicles with manual transmission put the gear shift lever in neutral. On vehicles with automatic transmission move the
selector lever to position "N". Turn appropriate wheel by hand. Remaining drive wheels must be secured against turning.
When a vehicle is accelerated uniformly on a dry surface, the displayed value will increase continuously by whole
numbers; e.g. 6 km/h, 7 km/h, 8 km/h ... . The difference between displayed values 1-4 should not be more than 1 km/h
(error from out-of-round wheels). If the values jump, for instance from ...6km/h, 7 km/h, to 12 km/h...or if the difference
between the displayed values is greater than 1 km/h, then check the installation of the wheel speed sensors and rotors.
Repair Manual, Brake System, Repair Group 45
Read measuring value block 1 Indicated on display

1 to 19 1) 1 to 19 1) 1 to 19 1) 1 to 19 1)
km/h km/h km/h km/h

Right rear ABS wheel speed sensor
Left rear ABS wheel speed sensor
Right front ABS wheel speed sensor
Left front ABS wheel speed sensor
1) On Board Diagnostic (OBD) is terminated by the ABS control module -J104- if road speed exceeds 19 km/h.
01-143
Note:
The display group numbers can be selected in

sequence by pressing buttons <-1 and 3-> on the
VAG1551 scan tool, or the arrow buttons and
on the VAG1552 mobile scan tool.
- Press -C- button to input display group number

manually.

01-144

0 or 1 0 or 1 0 or 1 ---
ABS solenoid valve relay:
0 not permitted during "Read measuring value block", the relay was not activated during "ignition
on".
- Electrical test, steps 1 and 2, check voltage supply page 01-166 . If no malfunction can be found
here, replace hydraulic control unit.
1 specified value, relay was activated by ABS control module -J104- during ignition on.
Voltage at motor for ABS return flow pump:
0 specified value, there is no voltage at the motor for the ABS return flow pump.
1 not permitted during "Read measuring value block", there is voltage at the motor for the ABS return flow
pump. Replace hydraulic control unit.
Brake light switch:
0 Brake pedal not operated - Check brake light switch if there are deviations. Carry out "Electrical test",
step 3 page 01-166 .
1 Brake pedal operated
01-145
Note:


manually.

Note:
For display group 3 (005):
To read the display fields for engine speed and current engine torque
with the engine running, communication between the scan tool and
the control module must be terminated via the "End Output" function
page 01-16 . Start the engine and reinitiate communication
between the scan tool and the control module.
function 08.
01-146

60 to 0 to 100 0 or 1 ---
8000
%
1 RPM
Traction control (ASR) button: (Only for vehicles equipped with ASR)
0 Traction control button not operated.

1 The traction control button is operated, operational condition of ASR alternates, i.e. "ASR
OFF" and "ASR ON".
- Check traction control button if there are deviations. Carry out "Electrical test", step 11 page 01-
166 .
Actual engine torque (AET): (Only for vehicles equipped with ASR)
0% vehicle is in deceleration mode.

20% - 30% represents engine idle.
100% engine is offering its maximum torque.
- If no indication is displayed, proceed according to DTC 00647 "ABS-ASR engine electrical connection 2".
Engine speed: (Only for vehicles equipped with ASR)
Engine speed is displayed in increments of 60 RPM, starting at 60 RPM.
- If no indication is displayed, proceed according to DTC 00529 "Wheel speed information missing. No signal". Diagnostic
Trouble Code (DTC) table
01-147
Note:


manually.

01-148

Std:min 0 or 1 0 or 1 ---
or too large
or ERROR
or invalid
EDL/ASR shut-off: (Only for vehicles equipped with EDL or ASR)
This possibility is only provided for development purposes.

0 EDL/ASR available
1 EDL/ASR not available
EDL shut-off due to excessive brake temperature: (Only for vehicles with EDL)
0 EDL was not shut off during the last 20x "ignition switched on and off".
1 EDL was shut off during the last 20x "ignition switched on and off".
Standing time: (Only for vehicles equipped with EDL)
too large: A standing time larger than 255 hours and 59 minutes is not indicated on the display.
ERROR: Two valid and matching time transmissions from the instrument cluster to the ABS control module (w/EDL) -
J104- did not occur after ignition was switched on and engine was started. Check whether the DTC 01203
"ABS/instrument cluster electrical connection" is stored in DTC memory.
Invalid: Standing time could not be obtained during this ignition cycle. Standing time calculation must be activated for at
least 20 seconds when the first component is operated for the first time when ignition is switched on after the instrument
cluster or the hydraulic control module have been replaced. The standing time will be indicated the next time ignition is
switched on.
Output Diagnostic Test Mode (DTM) (function 03) Page 1 of 66
01-149
Output Diagnostic Test Mode

(DTM) (function 03)
Output Diagnostic Test Mode (DTM) is used to
check the function of actuators. Actuators are
also called actors. These are components that
the control module activates when it reacts to the
signals sent by sensors.
"Function of actuators" includes all functions and

properties of an actuator under operating
conditions. This means, for example:
- An electrically operated hydraulic valves that

opens and closes when activated by the control
module.
- The relay of an electrical motor when activated

by the control module. The motor switches on
and carry outs the task.
Before initiating the output Diagnostic Test Mode

(DTM), make sure there are no electrical
malfunctions in the system you wish to test. This
will enable you to recognize any mechanical
problems. Perform a guided troubleshooting
before starting output Diagnostic Test Mode
(DTM) page 01-19 .
Are you sure there are no electrical malfunctions

in the system? If you have made sure that there
are no electrical malfunctions in the system, you
will be able to identify any mechanical

malfunctions in the individual actuators if the
results of the output DTM are not as specified
here. Replace the relevant part.
01-150
For Bosch 5.3 ABS/EDL, output Diagnostic Test

Mode (DTM) enables you to check the
electrically actuated hydraulic valves and the
pump motor in the hydraulic module. Also check
whether the brake lines are connected to the
proper brakes.
Notes:
The vehicle must be raised until all wheels are

free to turn. Ask a colleague to help. The
colleague will have to check the wheels to
determine whether they turn freely.
You can stop the test sequence at any time by

pressing the -C- button. If you wish to perform
output Diagnostic Test Mode (DTM) again after
this, communication must be interrupted via the
"End Output" function page 01-16 , and then
be re-established.
01-151
Notes:
To avoid overloading the components being

checked, they are actuated during the test
sequence for a period of 60 (or 90) seconds.
The actuator test will be terminated if the "
button" is not pressed within this period.
The ABS warning light and the red "brake

system malfunction" symbol blink during the
test.
Pressing the brake pedal repeatedly this

relieves the vacuum in the brake booster. For
this reason, the brake pedal must be pressed
harder in order to achieve the same braking
effect. Your work will be easier if you run the
engine briefly. This will build up vacuum in the
brake booster again.
01-152
During the test, the individual test steps are

shown in the second line of the VAG1551
scan tool display. The following
abbreviations are used.
IV = Inlet valve
OV = Outlet valve
LF = Left Front
RF = Right Front
LR = Left Rear
RR = Right Rear
B+ = Battery Positive Voltage (B+) at valve
0V = 0 volts; No voltage at valve
Locked/free = Wheel condition; must be checked

by second technician
Hydr-P = Hydraulic pump
01-153



Select function XX
(DTM)" function 03.

03 - Output Diagnostic Test Mode (DTM)
01-154
Output Diagnostic Test Mode (DTM) - Indicated on display:

ABS hydraulic pump -V64-
ABS/EDL hydraulic pump -V64- must start running. This is audible.
When you put your foot on the brake pedal you can feel it vibrating. The
brake pedal vibrates because the hydraulic pump generates pressure
pulses in the brake lines. The pressure pulses generate oscillations.
These are directed to the brake pedal and make it vibrate.
The pressure pulses in the brake lines are not sufficient to lock the
wheels.
The hydraulic circuit diagram shows a systematic representation of

an ABS/EDL system. This will give a better understanding of the
various test steps in the output Diagnostic Test Mode (DTM).
shaded components are in action.

Thin solid lines represent hydraulic lines or hoses that are not under
pressure.
Thick broken lines represent hydraulic lines or hoses working as
suction lines.
Thick solid lines represent hydraulic lines or hoses that are under
pressure.
- Press button.
01-155

Operate brake
- Press button.

Ifl: 0V Ofl: 0V fl wheel locked
When you press the brake pedal, brake fluid pressure will be built up in all
four calipers. All four wheels lock.
Requirement for this: mechanical/hydraulic components of the brake

system must be fully functional. This means that the master brake cylinder
is able to build up pressure in all wheel cylinders and the hydraulic
connections and lines are all sealed properly. If the wheels do not lock,
visually inspect brake fluid reservoir, master brake cylinder, hydraulic unit,
and calipers.
Concentrate on the left-front wheel first. The function of the control

elements for this wheel is tested first.
Note:
This test step in the output diagnostic test mode corresponds to the
"pressure build-up" phase during ABS-controlled braking.
01-156
- Press button.

Ifl: B+ Ofl: 0V fl wheel locked
Keep pressing brake pedal.
Inlet valve is activated. It interrupts the brake line. However, fluid pressure
is still maintained in the wheel cylinder. The left-front wheel remains
locked.
Note:
"maintain pressure" phase during ABS-controlled braking.
- Press button.
01-157

Ifl: B+ Ofl: B+ fl wheel free
Keep pressing brake pedal.
The inlet valve and the outlet valve for the left-front wheel are activated.
The hydraulic pump starts running and reduces the fluid pressure in the
caliper via the open outlet valve.
The brake pedal must not give, and should press harder against your
foot.
You should now be able to turn the left-front wheel.
If you cannot turn the wheel, check whether the brake line for the left-front
wheels is connected correctly. If yes, this indicates a mechanical
malfunction in one of the valves, providing there is no electrical
malfunction in the system. Replace hydraulic control unit.
If the pedal gives under your foot, this means that the inlet valve or the
check valve activated in parallel to the inlet valve is leaking. Replace
hydraulic control unit.
Note:
"pressure reduction" phase during ABS-controlled braking.
- Press button.
01-158

Ifl: B+ Ofl: 0V fl wheel free
ABS/EDL hydraulic pump -V64- will stop running.
Keep pressing brake pedal. Only the inlet valve is still activated and
interrupts the brake line. If the inlet valve is not leaking, you should be
able to turn the left-front wheel.
If you cannot turn the wheel, this means that the inlet valve or the check
valve activated in parallel to the inlet valve is leaking. Replace hydraulic
control unit.
- Press button.
01-159

Keep pressing brake pedal. Inlet valve is no longer being activated. It is

no longer interrupting the brake line. The brake pedal will give perceptibly
under your foot. Fluid pressure is built again in the left-front caliper. The
wheel will be locked.
- Press button.

Release brake
- Press button.
01-160
Continue output Diagnostic Test Mode (DTM)

in order to check the front right, rear left, and
rear right wheels in sequence. The test steps
indicate the procedure for the front left wheel.
They will therefore not be repeated in detail.

Operate brake
- Press button.

Ifr: 0V Ofr: 0V fr wheel locked
- Press button.

Ifr: B+ Ofr: 0V fr wheel locked
- Press button.
ABS/EDL hydraulic pump -V64- must start running.
The brake pedal must not give.

Ifr: B+ Ofr: B+ fr wheel free
- Press button.
01-161

Ifr: B+ Ofr: 0V fr wheel free
- Press button.
Brake pedal must give noticeably.

- Press button.

Release brake
- Press button.

Operate brake
- Press button.

Irl 0V Orl: 0V rl wheel locked
- Press button.

Irl B+ Orl: 0V rl wheel locked
- Press button.
01-162

Irl B+ Orl: B+ rl wheel free
- Press button.
ABS hydraulic pump -V64- will stop running.

Irl B+ Orl: 0V rl wheel free
- Press button.

- Press button.

Release brake
- Press button.

Operate brake
- Press button.
01-163

Irr: 0V Orr: 0V rr wheel locked
- Press button.

Irr: B+ Orr: 0V rr wheel locked
- Press button.

Irr: B+ Orr: B+ rr wheel free
- Press button.

Irr: B+ Orr: 0V rr wheel free
- Press button.

- Press button.

Release brake
- Press button.
01-164
Output Diagnostic Test Mode (DTM) - Indicated on display: Only significant for troubleshooting on
vehicles with EDL, starting with production deadline of calendar
EDL valves/ Hydr-P : B+ Wheel fl/fr lock
week 21/1997. For these vehicles, the test step was modified in
parallel to implementation of EBD emergency mode. Prior to
production deadline of calendar week 21/1997, the hydraulic pump is
not activated. This test step does not apply to vehicles without EDL.
The vehicle version, as relates to EBD, can be recognized by checking

the note column under "Check control module version"; page 01-128 .
The EDL change-over valve (left) and the EDL inlet valve are activated.
ABS return flow pump -V39- runs for one second. It draws brake fluid from
the brake fluid expansion tank via the EDL inlet valve. The hydraulic pump
builds brake fluid pressure in the EDL regulated wheel cylinders. These
wheels will then be locked.
If not, this indicates a mechanical malfunction in one of the valves,

providing there is no electrical malfunction in the system. Replace
This test step cannot be performed on vehicles that are not equipped with
EDL. These vehicles lack the EDL valves and the pressure relief valve.
01-165
- Press button.

End
Note:
The output diagnostic test mode is completed. The ABS/EDL warning light
and the red warning symbol for brake system go out.
- Press button.

Select function XX
Note:
If the ABS/EDL warning light does not go out, this indicates a
malfunction in the system. Observe test sequence exactly page 01-
17 .
01-166
Electrical testing
If the On Board Diagnostic (OBD) sequence

does not provide any indication of the source of
the malfunction, work through all of the
electrical test steps.
If the OBD sequence identifies the source of the

malfunction, only carry out the test steps
recommended in the DTC table (specific
testing).
Test requirements
The "Automatic Test Sequence" was carried

out and it was determined that the
Transmission Control Module (TCM) and
Engine Control Module (ECM) only contain
DTCs relating to ABS/EDL.

select the address word 00 with ignition
switched on;
- After completing electrical test, check and

erase DTC memories of Transmission Control
Module (TCM) and Engine Control Module
(ECM).
01-167
Multi-pin harness connector for ABS control module -J104- in proper

condition, with no bent, broken or corroded terminals. Replace any
damaged terminals using VAS1978 wiring repair kit.
Note:
The operation manual for the VAS1978 wiring harness repair kit generally
forbids the repair of any lines in the ABS or related systems. This rule only
pertains to the shielded lines in these systems.
Ignition and electrical consumers switched off before beginning

testing (headlights, lighting, fan, etc.).
01-168
Required special tools and test equipment:
VAG1598 test box
VAG1598/27 adapter
VAG1594 connector test kit
VAG1526 Multimeter
01-169
Connect VAG1598 test box using VAG1598/27

adapter.
- Connect VAG1598/27 adapter and VAG1598

test box. Disconnect multi-pin connector from
ABS control module -J104-. Connect
VAG1598/27 adapter and VAG1598 test box to
connector of ABS/EDL wiring harness.
The socket designations on the VAG1598 test

box are identical to the terminal designations on
the ABS control module -J104- and on the wiring
harness connector.

Component Locations
Terminal assignment of multi-pin connector at wiring harness / ABS

control module (w/EDL) -J104-
Note:
All terminals omitted here are not occupied at the moment and must not
be connected to other components!
01-170
Terminal Wire connection to component ...

1 Right rear ABS wheel speed sensor -G44-
for vehicles with Front Wheel Drive (FWD) and ABS/EDL/ASR

for vehicles with All Wheel Drive (AWD) and ABS/EDL
for vehicles with Front Wheel Drive (FWD) and ABS/EDL
3 Right front ABS wheel speed sensor -G45-
for vehicles with Front Wheel Drive (FWD) and ABS/EDL/ASR
for vehicles with Front Wheel Drive (FWD) and ABS/EDL

for vehicles with All Wheel Drive (AWD) and ABS/EDL

6 Left front ABS wheel speed sensor -G47-
7 Left front ABS wheel speed sensor -G47-
8 Left rear ABS wheel speed sensor -G46-
01-171

10 Electrical connection to instrument cluster
Only for vehicles equipped with EDL. The time signals used to calculate standing time are transmitted via
this harness connector
11 K-wire
13 MMD signal (Masked Misfire Diagnostic)
For vehicles equipped with ASR, the SET signal (Specified Engine Torque) is also transmitted via this wiring
harness.
14 Brake light switch -F-
15 Voltage supply, terminal 15
16 Ground (GND) terminal 31 (ABS hydraulic pump -V64-)
17 Battery + (terminal 30)
18 Battery + (terminal 30)
19 Ground (GND) terminal 31 (ABS control module -J104-)
20 Traction control (ASR) indicator light activation
Only for vehicles equipped with ASR.
21 ABS/EDL warning light activation

23 Speed sensor output rear left
For vehicles with navigation system
24 Speed sensor output rear right
For vehicles with navigation system
01-172

27 AET (Actual Engine Torque)
28 TI (Transmission Influence)
29 CAN-bus low
The CAN-bus wires transmit the following signals to the appropriate control modules: AET (Actual Engine
Torque), SET (Specified Engine Torque), TI (Transmission Influence) and engine speed.
30 CAN-bus high
The CAN-bus wires transmit the following signals to the appropriate control modules: AET (Actual Engine
Torque), SET (Specified Engine Torque), TI (Transmission Influence) and engine speed.
30 Engine speed (RPM)
31 Traction control (ASR) button
01-173
Notes:
For test table:
The socket designations of the VAG1598 test box are identical to the terminal designations of the ABS control module
(w/EDL) -J104- in the wiring diagram. Incorrect test procedures can cause damage to the system. Do not bridge any
terminals other than those listed in the table.
Specified values refer to readings on the VAG1526 and are not necessarily applicable for other test units.
If the measured values do not match specifications, carry out the corrective actions listed on the right side of the table.
If values are obtained, also check wiring for intermittent loose terminals and short circuit to B+ and Ground (GND). This
applies especially to sporadic malfunctions.
Use only the VAG1594 connector test kit for checking continuity (bridges).
If the measured values only differ slightly from the specifications, clean the sockets and harness connectors of the testers
and adapter leads (using contact spray G 000 700 04) and repeat the test. Before replacing actual components, check
wiring and connections once more. This is especially important if the specification for a resistance test is under 10 .
01-174
Test table
Set measurement range:
voltage test (20 V =)

Test VAG Test of Test Specified Corrective action
step requirements value
1598
sockets - Additional work
steps
1 19 + 15 Voltage supply to ABS Ignition 10.0 - 14.5 - Check wire from terminal 19 to
control module -J104- via switched on. V Ground (GND).
terminal 15
- Check wire from terminal 15 to
terminal 15.

Locations
01-175

1598
steps
2 16 + 17 Voltage supply of ABS hydraulic unit - 10.0 - 14.5
Ignition - Check wire from terminal
N55- and motor for ABS hydraulic V
switched on. 16 to Ground (GND).
pump -V64- via terminal 30 at ABS
control module (w/EDL) -J104-
16 + 18 10.0 - 14.5
- Check wiring from
V terminals 17 and 18 to B+
(terminal 30) via fuse (60A).

Troubleshooting &
Component Locations
01-176

Test VAG Test of Specified Corrective action
Test requirements
step value
1598 - Additional work
sockets steps
3 19 + 14 Function of brake Ignition switched - Check wire from terminal 19 to Ground
light switch -F- off (GND).
0.0 -0.5 V
Brake pedal not - Check wiring from terminal 14 to
depressed terminal 30 via fuse (10A).
- Operate brake pedal. - Check brake light switch -F-
10.0 - 14.5
V Electrical Wiring Diagrams,
- Adjust brake light switch -F-.
Repair Manual, Brake System, Repair

Group 45
01-177
Resistance measurement (2 k )
1598
steps
4 4 + 5 1) 2) Resistance of right - Check electrical wiring between control
front ABS wheel module and wheel speed sensor for open
speed sensor -G45-
3 + 5 3) circuit and for short circuit to Ground
(GND) or B+
5 6+7 Resistance of left Ignition 400 2300 - Check harness connectors.
front ABS wheel switched off
speed sensor -G47- - Move wire during test (loose contact).
(all Electrical Wiring Diagrams,

versions) Troubleshooting & Component Locations
- Replace the relevant ABS wheel speed

sensor if specified value is not obtained
and the electrical wiring is OK.
1) Assignment of wheel speed sensor terminals for vehicles with Front Wheel Drive (FWD) and equipped with EDL.
2) Assignment of wheel speed sensor terminals for vehicles with All Wheel Drive (AWD) and equipped with EDL.
3) Assignment of wheel speed sensor terminals for vehicles with Front Wheel Drive (FWD) and equipped with ASR.
01-178
Resistance measurement (2 k )
1598
steps
6 1 + 3 1) Resistance of right - Check electrical wiring between control
rear ABS wheel module and wheel speed sensor for open
speed sensor -G44-
1 + 2 2) 3) circuits and for short circuit to Ground
(GND) or B+
7 8+9 Resistance of left Ignition 400 2300 - Check harness connectors.
rear ABS wheel switched off
speed sensor -G46- - Move wire during test (loose contact).
(all Electrical Wiring Diagrams,

versions) Troubleshooting & Component Locations
- Replace the relevant ABS wheel speed

sensor if specified value is not obtained
and the electrical wiring is OK.
1) Assignment of wheel speed sensor terminals for vehicles with Front Wheel Drive (FWD) and equipped with EDL.
2) Assignment of wheel speed sensor terminals for vehicles with All Wheel Drive (AWD) and equipped with EDL.
3) Assignment of wheel speed sensor terminals for vehicles with Front Wheel Drive (FWD) and equipped with ASR.
01-179
Function test: ABS/EDL warning light -K47-

Test VAG Test of Specified Corrective
Test requirements
step value action
1598 - Additional work steps
sockets
8 - Function of ABS/EDL DTC memory checked and no DTC present
warning light -K47-. in DTC memory of ABS control module -
J104-.
Ignition switched off
Multi-pin connector connected to ABS
control module -J104- and retainer catch
engaged.
Test step 8: Continued on
next page.
01-180
Function test: ABS/EDL warning light -K47-

Test step VAG Test of Test Specified value Corrective action
requirements
1598
steps
8 - Function of ABS warning
- Switch on - If ABS/EDL warning light does not come
ABS/EDL light -K47- lights
ignition on, check voltage of electrical system and
warning light up for two (2) test wiring from terminal 21 of ABS control
-K47-. seconds and module -J104- to instrument cluster for
Continuation: then goes out. short circuit to Ground (GND).
- The ABS/EDL warning lamp does not
switch off after 2 seconds. The red "brake
system malfunction" symbol lights up after
2 seconds. Check wire from terminal 21 of
ABS control module -J104- to instrument
cluster for short circuit to B+ and open
circuit.

- If vehicle voltage and wire from terminal

21 of ABS control module -J104- to
instrument cluster are OK there is a
malfunction in instrument cluster, LED or
bulb malfunctioning.
Repair Manual, Electrical Equipment,

Repair Group 90.
01-181
Function test: Red brake warning symbol

Test requirements
step value action
sockets
9 - Function of red "brake
Brake fluid level is OK
system malfunction"
symbol
Group 47
Function of ABS warning light -K47-

already checked in step 8.
engaged.
Switch on ignition

next page.
01-182

Test step VAG Test of Specified value Corrective action
Test requirements
1598/20 - Additional work steps
sockets
9 Function of red The ABS indicator lamp
- Connect VAG1551 scan - Malfunction in
"brake system and the red "brake system
tool and select address instrument cluster
malfunction" malfunction" symbol light
word 03
symbol up. If the traction control
Continuation: - For vehicles with indicator light is installed Repair Manual,
automatic transmission and and OK, it also lights up. Electrical
high-line instrument cluster, Equipment, Repair
depress the brake pedal Group 90;
and select a driving gear. instrument cluster.
01-183
Function test: Traction control indicator light -K86-, only installed on vehicles equipped with ASR
Test requirements
step value action
sockets
10 - Function of traction DTC memory checked and no DTC
control indicator light - present in DTC memory of ABS control
K86- module -J104-.
engaged.
next page.
01-184
Function test: Traction control indicator light -K86-, only installed on vehicles equipped with ASR
requirements
1598
steps
10 - Function of Traction control
- Switch on - If traction control indicator light does
traction indicator light -K86-
ignition not light up, check vehicle voltage and
control comes on for two wire from terminal 20 of ABS control
indicator light (2) seconds and module -J104- to instrument cluster for
Continuation: -K86- then goes out. short circuit to B+ and open circuit.
- If traction control indicator lights
continuously, test wire from terminal 20
of ABS control module -J104- to
instrument cluster for short circuit to
Ground (GND).

Locations
- If vehicle voltage and wire from

terminal 20 of ABS control module -
J104- to instrument cluster are OK
there is a malfunction in instrument
cluster, LED or bulb malfunctioning.
Repair Manual, Electrical Equipment,

Repair Group 90; instrument cluster.
01-185
Function test: Traction control button; set measurement range on VAG1526: 20 V =

Test VAG Test of Specified value Corrective action
Test requirements
step
sockets
11 - Function of
traction control
button Function of traction control
indicator light -K86- was
Multi-pin connector connected
to ABS control module -J104-
and retainer catch engaged.
- Switch on ignition
Traction control
- Press traction control button - Switch off ignition.
indicator light -
K86- lights up - Detach multi-pin
connector from ABS control
module -J104- and remove.
Traction control
- Press traction control button - Connect VAG1598 test
indicator light -
again box using VAG1598/27
K86- goes out. adapter.
Test step 11: Continued on next page.
01-186

Test step VAG Test of Specified Corrective action
Test requirements
value
1598 - Additional work
sockets steps
11 19 + 31 Function of Ignition switched

traction control on.
button
Continuation: 0.0 -0.5 V
- Traction control
button not pressed
10.0 - 14.5
- Traction control - Check wire from terminal 19 to Ground
V
button pressed (GND).
- Check wire from terminal 31 to traction
control button, terminal 6.
- Check voltage supply from terminal 5
of traction control button to terminal 15.

- If no malfunctions can be found using

the procedures in these steps, replace
the traction control button.
01-187
Notes:
Fulfill test requirements page 01-22 .
Connect the VAG1551 Scan Tool (ST) and select "Brake Electronics" via address word 03 page 01-4 .
Check the control module version page 01-128 and press the button.
Press buttons -0- and -2- to select "Check DTC Memory" function 02. Press -Q- button to confirm input.
Notes:
Each malfunction is assigned a 5-digit Diagnostic Trouble Code (DTC). The DTC is located in the left column of the DTC
table. If you have switched the printer on by pressing the "PRINT" button, the VAG1551 scan tool (ST) prints the message
identifying the malfunction and the DTC. Otherwise, DTCs are not displayed by the VAG1551 scan tool.
The contents of DTC memory remain stored until memory is erased, page 01-15 .
Sporadically occurring malfunctions are identified via indication of "/SP" on the right-hand side of the display.
Static malfunctions that cannot be detected when the vehicle is stationary are also identified with "/SP" if the ignition has
been switched off and then on again.
The following DTC table includes all the DTCs that can be stored by the ABS control module -J104- and displayed and
printed out by the VAS5051 tester or VAG1551 scan tool. Malfunctions are listed by DTC number.
01-188

Printed output from
VAG1551 Scan Tool (ST)
00000
No malfunction recognized!
If this display appears, Voltage supply for ABS control module - - See section "Overview of indicator lamp
process is concluded. No J104- below 10.0 volts at a vehicle speed functions" page 01-120 .
DTCs are stored in DTC less than 6 km/h.
memory.
Open circuit in activation wire for ABS
If corresponding warning warning light -K47- between ABS control
lamps light up anyway, check module (w/EDL) -J104- and instrument
the following points: cluster combination processor -J218-.
If no malfunction can be found, and there is still - Expand troubleshooting to include
a problem, there may be a mechanical output Diagnostic Test Mode (DTM)
malfunction (e.g. solenoid valve sticking). page 01-149 and the "Electrical test"
page 01-166 .
01-189

Printed output from
VAG1551 Scan Tool
(ST)
00283
Left front ABS wheel Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
speed sensor -G47-
1)
G47- installed incorrectly.
ABS wheel speed sensor rotor dirty or Repair Manual, Brake System, Repair Group 45
Mechanical damaged.
malfunction - Check rotor, clean or replace
Excessive wheel bearing play.
or: ABS wheel speed sensor -G47- Repair Manual, Brake System, Repair Group 45
malfunctioning.
- Replace wheel bearing
Short circuit to Ground (GND).
Repair Manual, Suspension, Wheels, Steering,
Repair Group 40
- "Read measuring value block" display group 1

page 01-140 .
- Carry out "Electrical test", step 5 page 01-166 .
Left front ABS wheel Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
speed sensor -G47- wiring between ABS wheel speed block", and no malfunction could be determined in the
sensor -G47- and ABS control module - wiring or the ABS wheel speed sensor, replace the
Open circuit/short J104-. hydraulic control unit.
circuit to B+
1) This malfunction can only be detected when the vehicle is moving
01-190

Printed output from
VAG1551 Scan Tool
(ST)
00285
Right front ABS Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
wheel speed sensor G45- installed incorrectly.
-G45-1)
Mechanical damaged.
malfunctioning.
Repair Group 40

page 01-140 .
Right front ABS
Incorrect control module version. - Check control module version page 01-128 .
wheel speed sensor
-G45- Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
wiring between ABS wheel speed block", and no malfunction could be determined in the
Open circuit/short sensor -G45- and ABS control module - wiring or the ABS wheel speed sensor, replace the
circuit to B+ J104-. hydraulic control unit.
01-191

Printed output from
VAG1551 Scan Tool
(ST)
00287
Right rear ABS Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
-G44-1)
Mechanical damaged.
malfunctioning.
Repair Group 42

page 01-140 .
Right rear ABS
Incorrect control module version. - Check control module version page 01-128 .
wheel speed sensor
circuit to B+ J104-. hydraulic control unit.
01-192

Printed output from
VAG1551 Scan Tool
(ST)
00290
Left rear ABS wheel Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
speed sensor -G46- G46- installed incorrectly.
1)
Mechanical damaged.
malfunctioning.
Repair Group 42

page 01-140 .
Left rear ABS wheel Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
Open circuit/short J104-. hydraulic control unit.
circuit to B+
01-193

Printed output from VAG1551 Scan
Tool (ST)
00301
ABS return flow pump -V39 -
Malfunction in hydraulic - Erase DTC memory page 01-15
control unit
- End Output page 01-16 .
- Switch on ignition
- If malfunction occurs again, replace hydraulic

control unit.
01-194

Printed output from
00526
Brake light switch -F-
Open circuit
Both brake lights -M9- (left) and - - Check brake light switch, "Read measuring value
M10- (right) malfunctioning. block", display group 2 page 01-140 .
Wire from brake lights to control - Locate and repair open circuit or short circuit.
module faulty.
- Replace bulbs.
ABS control module -J104-
malfunctioning Electrical Wiring Diagrams, Troubleshooting &
Component Locations
01-195

Printed output from
VAG1551 Scan Tool
(ST)
00529
Wheel speed information Data is transferred between the ABS For more information, see the section "Systems
missing control module -J104- and the Engine related to ASR" page 01-42 and the table
Control Module (ECM) via a single wire. "Control module versions" page 01-134 .
This malfunction only

occurs if vehicle is
equipped with ASR.
See continuation on next
page
Open circuit or short circuit to B+ or - Locate and repair open circuit or short circuit.
Ground (GND) in wire between ABS
control module -J104- and Engine Electrical Wiring Diagrams, Troubleshooting &
Control Module (ECM). Component Locations
Engine Control Module (ECM) - If the tachometer in the instrument cluster is

malfunctioning. malfunctioning and no malfunctions can be found
in the wiring, the Engine Control Module (ECM)
is malfunctioning.
ABS control module -J104-

malfunctioning - If the tachometer in the instrument cluster
functions properly and no malfunctions can be
found in the wiring, the ABS control module
(w/EDL) -J104- is malfunctioning.
01-196

Printed output from
VAG1551 Scan Tool
(ST)
00529
Wheel speed information Data is transferred between ABS For more information, see the section "Systems related
missing control module -J104- and Engine to ASR" page 01-42 and the table "Control module
Control Module (ECM) via the versions" page 01-134 .
CAN-bus.
Continuation:
This malfunction only

equipped with ASR.
The Engine Control Module - Check DTC memory of Engine Control Module (ECM).
(ECM) is not able to provide the If there is a malfunction, fix it according to the
engine speed (RPM) signal for appropriate engine Repair Manual and erase DTC
the CAN-bus. memory of the Engine Control Module (ECM).
- If there are no DTCs stored in the Engine Control
Module (ECM), replace the Engine Control Module
(ECM) as a test.
The ABS control module - If the steps listed above do not repair the malfunction,
(w/EDL) -J104- is not able to replace the ABS control module -J104-.
evaluate the engine speed
(RPM) signal for the CAN-bus.
01-197

Printed output from VAG1551 Scan Tool
(ST)
00532
Voltage supply
Open circuit or contact resistance - Carry out "Electrical test", step
too high between voltage supply 1 page 01-166 .
Signal too small from terminal 15 hydraulic control
unit, terminal 15. - Locate and repair open circuit
in voltage supply.
Voltage jumps in vehicle system.
Notes: Electrical Wiring Diagrams,
This malfunction affects the voltage supply Locations
of the control module.
- Check Generator (GEN) and
This DTC is only stored, if the malfunction
Voltage Regulator (VR).
occurs at a vehicle speed above 6 km/h.
As soon as vehicle voltage is within the Electrical Wiring Diagrams,
valid voltage range again, the ABS/EDL or Troubleshooting & Component
ASR system is switched back on and the Locations
warning lights turn off.
- Check battery
Repair Manual, Electrical

Equipment, Repair Group 27.
Malfunction in hydraulic control unit - If no malfunctions can be

found in the voltage supply,
replace hydraulic control unit.
01-198

Printed output from
00597
Varying wheel speed
Wheel or tire sizes not the same on all four - Check wheel and tire sizes.
impulse wheels.
ABS wheel speed sensor rotor dirty or - Check rotor.

damaged.
Group 45
Excessive wheel bearing play. - Check wheel bearing
Repair Manual, Suspension, Wheels,

Steering, Repair Group 40

ABS wheel speed sensors -G44-, -G45-, -G46- - Check ABS wheel speed sensors.
, and -G47- installed incorrectly.
ABS wheel speed sensors -G44-, -G45-, -G46- Repair Manual, Brake System, Repair
, and -G47- malfunctioning Group 45
- Carry out "electrical test", steps 4

through 7 page 01-166 .
01-199

Printed output from
VAG1551 Scan Tool
(ST)
00623
ABS / transmission Data is transferred between the ABS control For more information, see the section
electrical connection module -J104- and the Transmission Control "Systems related to ASR" page 01-42
Module (TCM) via a single wire. and the table "Control module versions"
This malfunction only page 01-134 .
equipped with ASR.
Manual transmission
ABS/EDL/ASR control module -J104- - Check coding of ABS/EDL/ASR control

incorrectly coded. module -J104- page 01-135 .
Short circuit to B+ - Locate and repair short circuit.

Automatic transmission
ABS/EDL/ASR control module -J104- - Check coding of ABS/EDL/ASR control

incorrectly coded. module -J104- page 01-135 .
Open circuit or short circuit to Ground (GND) - Locate and repair open circuit or short
in wiring between ABS/EDL/ASR control circuit.
module -J104- and Transmission Control
Module (TCM) -J217-. Electrical Wiring Diagrams,
01-200

Tool (ST)
00646
ABS-ASR motor electrical connection Data is transferred between the ABS For more information, see the section
1 control module -J104- and the Engine "Systems related to ASR" page 01-
Control Module (ECM) via a single wire. 42 and the table "Control module
versions" page 01-134 .
Note: Open circuit or short circuit to B+ or - Locate and repair open circuit or
Ground (GND) in wiring between ABS short circuit.
The following signals are sent from control module -J104- terminal 13 and
the ABS control module (w/EDL) - Engine Control Module (ECM).
J104- to the Engine Control Module Electrical Wiring Diagrams,
(ECM) via this connection: Troubleshooting & Component
Locations
MMD signal (Masked Misfire ABS/EDL/ASR control module -J104- - Replace ABS/EDL/ASR hydraulic
Diagnostic) for On Board malfunctioning. control unit.
Diagnostic (OBD)
SET signal (Specified Engine
Torque)
ETR signal (Engine Torque Engine Control Module (ECM) - Replace Engine Control Module
Reduction signal) malfunctioning. (ECM).
01-201

Printed output from VAG1551
Scan Tool (ST)
00647
ABS-ASR motor electrical Data is transferred between the ABS For more information, see the section
connection 2 control module -J104- and the Engine "Systems related to ASR" page 01-42
Control Module (ECM) via a single wire. and the table "Control module versions"
page 01-134 .
Note: Open circuit or short circuit to B+ or - Locate and repair open circuit or short
Ground (GND) in wiring between ABS circuit.
The following signal is sent from control module -J104- terminal 27 and
the Engine Control Module (ECM) Engine Control Module (ECM).
to the ABS control module (w/EDL) Electrical Wiring Diagrams,
-J104- via this connection: Troubleshooting & Component
Locations
AET signal (Actual Engine Engine Control Module (ECM) - Replace Engine Control Module
Torque) malfunctioning. (ECM).
ABS/EDL/ASR control module -J104- - Replace ABS/EDL/ASR hydraulic

malfunctioning. control unit.
01-202

Printed output from
VAG1551 Scan Tool
(ST)
00761
DTC stored in Engine Data is transferred between ABS For more information, see the section "Systems
Control Module (ECM) control module -J104- and Engine related to ASR" page 01-42 and the table "Control
Control Module (ECM) via a single module versions" page 01-134 .
This malfunction only wire or via the CAN-bus.
equipped with ASR.
A DTC was stored in the Engine - Check DTC memory of Engine Control Module
Control Module (ECM). The Engine (ECM). Repair the malfunction according to the
Control Module (ECM) is not able to appropriate engine Repair Manual and erase DTC
reduce engine torque. memory of the Engine Control Module (ECM).
01-203

Printed output from
01044
Control module incorrectly Data is transferred between the ABS control For more information, see the section
coded module -J104- and the Transmission Control "Systems related to ASR" page 01-42 and
Module (TCM) via the CAN-bus. the table "Control module versions" page
This malfunction only 01-134 .
equipped with ASR.
The ABS control module (w/EDL) -J104- is - Code the ABS control module (w/EDL) -
coded for a vehicle with manual J104- for the correct transmission page
transmission. The vehicle is equipped with 01-135 .
automatic transmission.
01130
ABS operation - Replace the ABS control module (w/EDL) -
J104- after conferring with the product
Implausible signal department of your distributor or with the
responsible importer.
01-204

Tool (ST)
01200
Supply voltage for ABS valves
Open circuit or contact resistance too - Carry out "Electrical test", step
high between voltage supply from 2 page 01-166 .
terminal 30 hydraulic control unit,
terminals 17 and 18. - Locate and repair open circuit in
Note: voltage supply.
Voltage jumps in vehicle system.
This malfunction affects the voltage Electrical Wiring Diagrams,
supply of the ABS hydraulic unit -N55- Troubleshooting & Component
and the motor for the ABS hydraulic Locations
pump -V64-.
Voltage Regulator (VR).

Locations
- Check battery

Equipment, Repair Group 27.
Malfunction in hydraulic control unit - If no malfunctions can be found

in the voltage supply, replace
01-205

Printed output from VAG1551
Scan Tool (ST)
01201
Supply voltage for ABS pump
Open circuit or contact resistance too - Carry out "Electrical test", step 2
high in Ground (GND) supply to page 01-166 . Check contact resistance
hydraulic control unit, terminal 16. in the Ground (GND) supply.
Note: - Locate and repair open circuit in
Ground (GND) supply.
This malfunction affects the Ground
(GND) supply of the motor for the Electrical Wiring Diagrams,
ABS hydraulic pump -V64-. Troubleshooting & Component Locations
Malfunction in hydraulic control unit - If no malfunctions can be found in the

voltage supply, replace hydraulic control
unit.
01-206

Printed output from
VAG1551 Scan Tool
(ST)
01203
ABS / instrument cluster
electrical connection
Open circuit/short circuit Short circuit to Ground (GND) or open circuit in wire - Check the wire for short circuit to
to Ground (GND) between instrument cluster and hydraulic control Ground (GND) and for open circuit.
unit, terminal 10.
Locations
Rear window heating, electrical testing Page 1 of 5
01-153
Rear window heating,

electrical testing
Note:
Only perform this test on A/C control heads -E87-

with only one display (switch for rear window
heating is integrated in the A/C control head -
E87-).
Special tools and equipment
VAG1715 multimeter (with voltage probe)
VAG1594A Measuring Appliance Adapter
Test requirements
All fuses OK

- Remove A/C control head -E87- page 87-

120 .
- Disconnect harness connector E from A/C

control head -E87-.
- Connect multimeter between terminal 1 and 2 for voltage

measurement.
01-154
- Turn ignition on.
Specification: approx. battery voltage
- Connect harness connector E at A/C control

head -E87-.
- Route wire -A- to harness connector E through current probe on

VAG1715.
Note:
All harness connectors at A/C control head -E87- must be connected.
- Select "Amperage measurement via amperage probe" function on

VAG1715 (with voltage probe).
01-155
- Start engine.
- Switch rear window heating on via A/C control

head -E87- (indicator lamp in button lights up).
Specified value: The display on VAG1715 will

change from approx. 0 amps to less than 25
amps.
- Wait approx. 10 minutes.
Specified value: The display on the VAG1715

will change from less than 25 amps to approx. 0
amps (indicator lamp in button goes out).
Notes:
The current probe may be influenced by stray

current which could cause the display to show a
low current reading when rear window heating
is switched off.
The A/C control head -E87- will switch rear

window heating off after 10 minutes.
When the outside temperature is less than 0 C

the heating function of the rear window will
remain on until the ignition is switched off (it can
be turned off manually at any time). If the

temperature while driving exceeds 0 C, the
rear window heater is turned off after the
operating time stored in -E87- (max. 10
minutes) elapses.
Output Diagnostic Test Mode (DTM) (scan tool function 03) Page 1 of 18
01-163
Output Diagnostic Test Mode

(DTM) (scan tool function 03)
Note:
There are two different transmissions:
Transmission with hydraulic controls -E17-, on

which the transmission input speed sensor
(inductive sensor) is secured to the underside
of the valve body.
Transmission with hydraulic regulation -E18/2-,

on which the transmission input speed sensor
(camshaft position sensor) is secured behind
the valve body at the transmission housing.
For information on which transmission is

installed, refer to tables from the following Repair
Manual:
Repair Manual, 5 Spd. Automatic

Transmission 01V, Repair Group 00
Output Diagnostic Test Mode (DTM) for

transmission with hydraulic regulation -E17-
page 01-164
Output Diagnostic Test Mode (DTM) for

transmission with hydraulic regulation -
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.AT02.01.10 11/20/2002
E18/2- page 01-171
01-164

(scan tool function 03), transmissions
with hydraulic regulation -E17-
Note:
The Output Diagnostic Test Mode (DTM) can

only be performed when the ignition is switched
off, the selector lever is in position "P", the
engine is not running, and the vehicle is
stationary.
DTM will be terminated when the engine is

started.
The function of solenoid valves 1 -N88-, 2 -N89-

, 3 -N90- and the solenoids for the selector
lever lock are checked acoustically during the
DTM. Avoid noise in the surrounding area
during the acoustic check, because the
switching noise (clicking) of the actuators is
very quiet.
The solenoid valves 4 -N91-, 5 -N92-, 6 -N93-

and 7 -N94- are activated during the DTM. A
direct functional check of these valves is not
possible. But possible electrical faults which
occur during the activation, will be recognized
by the On Board Diagnostic (OBD) and stored
in the DTC memory.
01-165
When performing the Output Diagnostic Test

Mode (DTM), the individual actuators will be
activated until the button is pressed.
Only one complete DTM is possible after

switching the ignition on. To repeat DTM, the
ignition must be switched off and on again.
Activation sequence
1. Solenoid Valve 1 -N88-
4. Shift Lock solenoid -N110-
9. Kick-down Switch -F8-
(Kick-down for air conditioner)

10. Solenoid Valve Relay
01-166
Test sequence
- Connect VAS 5051 tester or V.A.G 1551 scan

tool and enter address word 02 for "Control
module for Transmission electronics" page
01-40 .
Ignition must be switched off during this

process.

Select function XX
- Press keys 0 and 3. (03 selects the function "Output Diagnostic Test
Mode").

- Press Q- button to confirm entry.
Output Diagnostic Test Mode -

Solenoid valve 1 -N88
- Valve is activated (clicks). To switch to next actuator press key.
- If valve does not click, perform electrical check Page 01-273 .
Malfunction is stored in DTC memory, see DTC table Page 01-45 .
01-167

- Valve is activated (clicks) To switch to next actuator press key.

Malfunction is stored in DTC memory, DTC table Page 01-45 .

Selector lever lock solenoid -N110
- Solenoid is activated (clicks). Switch to next actuator press key.
- If solenoid does not click, perform electrical check Page 01-273 .
Malfunction is stored in DTC memory, DTC table Page 01-45 .
01-168

Electrical malfunctions will be stored in DTC memory. See DTC table

Page 01-45 .


Page 01-45 .

- Valve is activated (clicks). Switch to the next actuator press key.

Page 01-45 .
01-169


Page 01-45 .

Kick-down switch -F8
Notes:
It is not the kick-down switch -F8-, but the switch-off function for the air
conditioner in transmission control module -J217- which is activated.
If the kick-down switch is operated, the Transmission Control Module
(TCM) grounds the output to air conditioner. This briefly switches off
the air conditioner compressor.
Can be disregarded here.
The signal can be checked in measured value block 011 01-186 .
For checking function of Kick-down switch -F8- Page 01-273
Electrical check.
- Press key to switch to the next actuator.
01-170

Solenoid valve relays
- Solenoid valves activated in position "P" are activated (click), press
key to switch to the next actuator.
Can be disregarded.
- Press key.

End
- Press key
Function is unknown or Indicated on display

cannot be performed at this time
- Pressing the key will terminate the Output Diagnostic Test Mode.

Select function XX
- To repeat Output Diagnostic Test Mode, the ignition must be switched
off and then on again. Now select function 03 - Output Diagnostic Test
Mode again.
01-171

(scan tool function 03), transmissions
with hydraulic regulation -E18/2-
Note:
The Output Diagnostic Test Mode (DTM) can

only be performed when the ignition is switched
off, the selector lever is in position "P", the
engine is not running, and the vehicle is
stationary.
DTM will be terminated if the engine is

started.
The function of solenoid valves 1 -N88-, 2 -N89-

, 3 -N90- and the solenoids for the shift lock are
checked acoustically during DTM. Avoid noise
in the surrounding area during the acoustic
check, because the switching noise (clicking) of
the final controls is very quiet.
The pressure control valves 1 -N215-, 2 -N216-,

3 -N217- and 4 -N218- are activated during
DTM. A direct functional check of these valves
is not possible. But possible electrical faults
which occur during the activation will be
recognized and stored in DTC memory.
01-172
When performing the Output Diagnostic Test

Mode (DTM) the individual actuators will be
activated until the button is pressed.
Only one complete DTM is possible after

switching the ignition on. To repeat DTM, the
ignition must be switched off and on again.
Activation sequence
4. Shift Lock solenoid -N110-
5. Pressure Control Valve -1- for Auto.
Transmission -N215-
Transmission -N216-
Transmission -N217-
Transmission -N218-
9. Voltage supply for solenoid valves
01-173
Test sequence

tool and enter address word 02 for "Control
module for transmission electronics" page 01-
40 .
Ignition must be switched off during this process.

Select function XX
- Press keys 0 and 3. (03 selects function "Output Diagnostic Test
Mode").

- Confirm entry with Q button.
Output Diagnostic Test Mode (DTM) Indicated on display:

Shift valve 1 Solenoid Valve 1 -N88
- Valve is activated (clicks), to switch to the next actuator press key.
Malfunction is stored in DTC memory, see DTC table Page 01-45
01-174

- Valve is activated (clicks) To switch to next actuator press key.
- If the valve does not click, perform electrical check Page 01-273 .

- Valve is activated (clicks). To switch to the next actuator press key.

Shift lock Solenoid -N110
- Solenoid is activated (clicks). To switch to the next actuator press
key.
- If solenoid does not click, perform electrical check Page 01-273 .
Malfunction is stored in DTC memory, DTC table Page 01-45
01-175

Press. control valve -1- for auto. trans. -N215
- Pressure control valve -N215- is activated (clicks). To switch to the
next actuator press key.
Electrical malfunctions will be stored in DTC see DTC table Page
01-45 .

Press. control valve -2- for auto. trans. -N216
- Pressure Control valve -N216- is activated (clicks). To switch to the
Electrical malfunctions will be stored in DTC, see DTC table Page
01-45 .

Press. control valve -3- for auto. trans -N217
- Pressure Control valve -N217- is activated (clicks). To switch to the
Electrical malfunctions will be stored in DTC, see DTC table Page
01-45 .
01-176

Press control valve -4- for auto. trans. -N218
- Pressure Control valve -N218- is activated (clicks) To switch to next
actuator press key.
Electrical malfunctions will be stored in DTC memory, see DTC
table Page 01-45
Note:
Output Diagnostic Test Mode (DTM) "Pressure Regulating Valve -5- for Automatic Transmission -N233-" could
Press reg. valve -5- for auto trans. -N233 now be displayed erroneously due to a software error, even though it
does not exist. Disregard this display. Press button to switch to the next
actuator.

Voltage supply for solenoid valves
Solenoid valves activated in position "P" are activated (click). Press key
to switch to the next actuator.
Can be disregarded.
- Press key.
01-177
Function is unknown or Indicated on display

cannot be carried out at the moment
- Pressing the key will terminate Output Diagnostic Test Mode.

Select function XX
- To repeat Output Diagnostic Test Mode, switch ignition off and then on
again. Now select function 03 - Output Diagnostic Test Mode again.
01-178
DTC Memory, erasing (scan tool

function 05)
Requirement:
DTC memory checked page 01-43 .
After DTC memory has been checked:

Select function XX
- Press keys 0 and 5. (With function 05 "Erase DTC memory" is entered)

05 Erase DTC memory
- Confirm entry with Q button.
WARNING! Indicated on display:

Note:
If the ignition was switched off e.g. between checking the DTC memory
and erasing DTC memory, the DTC memory is then not erased.
- Exactly follow the work sequence. The DTC memory must first be
checked.
01-179
Rapid data transfer Indicated on display:

(The DTC memory will be erased approx. 5 seconds. after the display
appears.)
The DTC memory is now erased.
Note:
Wait about 1 minute before checking the DTC memory again.
System cannot be checked! Indicated on display:
1 Fault recognized ! Print out with printer switched on:

00811 3333
System cannot be checked

Transmission Control Module (TCM) -J217- was not given sufficient time
to recognize faults.
- Wait about 1 minute before checking the DTC memory again.

- After checking and erasing DTC memory, test drive the car and check
DTC memory again.
When the DTC memory is being checked, the following display should
appear:
"No DTC recognized!"
Transmission Control Module (TCM), coding (scan tool function 07) Page 1 of 9
01-180
Transmission Control Module

(TCM), coding (scan tool
function 07)
Procedure
- Connect VAS5051 tester or V.A.G1551 scan

tool and select Transmission Control Module
(TCM) using "address word" 02 page 01-40 .
Ignition must remain switched on.

Select function XX
Print out control module identification:
- Switch on printer by pressing print button (indicator lamp in button

lights up).
8D0927156BT AG5 01V 2.8l 5V USA 1416 Indicated on display

Control module identification is displayed:
Depending on the control module version (software version), the control

module may indicate a different identification than shown in this example.
For allocation of control module
Parts catalog
01-181
Explanation of display:
8D0927156BT: Part number
AG5 01V: Automatic Transmission, 5-speed

01V
2,8l 5V: Engine type
USA: Market, USA and Canada
1416: 14 = software version, 16 = data

version
Coding 00002: Coding (see Coding tables

page 01-184 )
WSC 00000: Factory identification of

V.A.G1551, with the last coding that was
performed
- Press button.
TCM identification can only be printed out when

printer is switched on.

Select function XX
Note:
Read Transmission Control Module (TCM) identification to determine

which transmission/engine combination is present in this case, see
explanation above. Then use coding table to determine whether the
appropriate code was entered.
- Press buttons -0- and -7-. This selects "Coding Control Module",
function 07.
01-182
Note:
Coding can only be performed with ignition on

and selector lever in position "P" or "N".
Accelerator pedal must be in idle position.
Vehicle must be stationary and engine must not
be started.

07 Code control module
Code control module HELP Indicated on display

- Enter code
Note:
Find control module identification in coding tables starting on page 01-

184 and enter it into tester. The Dynamic Shifting Program (DSP) should
remain on at all times if possible.
Note:
DTC memory in the control module is automatically erased following

coding.
- Press button.

Select function XX
- Check TCM version (press buttons -0- and -1-), confirm input with Q
button and check coding page 01-34 .
01-183
DTC When indicated on display: An attempt was made to enter a code that is
Coding XXXXX not accepted
not valid or unrecognized by the control module.
Note:
If a wrong code was entered, the control module will retain the old
code.
8D0927156BT AG5 01V 2.8l 5V USA 1416 Indicated on display

Note:
A control module identification that has been wrongly entered is only
indicated alongside the old coding for older V.A.G1551 tester cards.
Function is unknown or cannot be When indicated on display:

carried out at the moment
An attempt was made to perform coding in an unauthorized coding
condition, e.g. with the vehicle was being driven.
01-184
Coding tables
For vehicles without E-gas
Code Transm. Engine Dynamic Shift Market

Code Program (DSP)
00000 DDT All valid engine/transmission combinations without E-gas DSP active Rest of world and
USA FWD and
DKB This information is in the following repair manuals: Quattro
DRD Repair Manual, 5 Spd. Automatic Transmission 01V,

Repair Group 00, engine codes, engine/transmission
DRN allocation, ratios, equipment
DTV
01-185
For vehicles with E-gas
Code Engine Dynamic Shift Market

Program (DSP)
00000 Not permitted code
00001 All valid engine/transmission combinations with E-gas DSP active Rest of world
Quattro
00002 This information is in the following repair manuals: DSP active USA Quattro
00003 Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00, DSP active Rest of world
engine codes, engine/transmission allocation, ratios, equipment FWD
00004 DSP active USA FWD
Read Measuring Value Block (scan tool function 08) Page 1 of 1
01-186

(scan tool function 08)
Notes:
There are two types of transmissions:
1. Transmissions with hydraulic control -E17-:

The sensor for transmission RPM (inductive
sensor) is secured to the bottom of the valve
body.
2. Transmissions with hydraulic control -E18/2-:

The sensor for transmission RPM (hall effect
sensor) is secured to the transmission housing
behind the valve body.
Information about which transmission is installed

Transmission 01V, Repair Group 00, engine
codes, engine/transmission allocation, ratios,
equipment
Read measuring value block for transmission

with hydraulic control -E17- page 01-187
Read measuring value block for transmission

with hydraulic control E18/2 page 01-228
Read Measuring Value Block (scan tool function 08) for transmissions with hydraulic control -E17- Page 1 of 49
01-187

(scan tool function 08) for
transmissions with hydraulic
control -E17-
Note:
For transmissions with hydraulic control -E18/2-,

"Read Measuring Value Block" page 01-228
WARNING!
To avoid accidents during measuring and test

drives, observe safety precautions page
01-34 .
Procedure
- Connect VAS 5051 tester or V.A.G 1551 Scan

Tool (ST) and select Transmission Control
Module (TCM) using "address word" 02 page
01-36 . Ignition must remain switched on.

Select function XX
- Press PRINT button to turn on ST printer. Indicator lamp in button must
light up.
01-188
Read measuring value block Q When indicated on display:

- Enter desired display group number, display group overview, page
01-189 .
- Press Q button to confirm input.
Read measuring value block 1 Indicated on display (example) for display group 001:
1234
Notes:
Explanation of values in the individual display fields Test table page
01-194 .
Display can be printed out when printer is switched on.
Display group V.A.G 1551 VAS 5051 tester

- If specified values are obtained in all display fields, press button.

Select function XX
01-189
Overview of selectable display group numbers for transmission with hydraulic control -E17-
Indicated on display (example)

Display fields: Display group no. Display field Description
1234
JJJ
Read measuring value block 1 001 1 Engine speed (RPM)
2 Sensor for Transmission RPM -G182-
0 RPM 0 RPM 0 RPM 4 3 Transmission Vehicle Speed Sensor -G38-
4 Driving range selected

Read measuring value block 2 002 1 Dynamic code number
2 Throttle valve value
0 0 % 0 RPM 4 3 Transmission Vehicle Speed Sensor -G38-

Read measuring value block 3 003 1 Brake
2 "P" "N" lock
PN active 0 km/h 12.8 V 3 Speed
4 Supply voltage pin 54, 55
01-190

1234
Read measuring value block 4 004 1 ATF temperature
2 Selector lever position
21.0 C P 1000 3 Multi-function switch position
4 On Board Diagnostic (OBD) 1) information
Request for engine intervention2)

Read measuring value block 5 005 1 Solenoid valve 1 -N88-
2 Solenoid valve 2 -N89-
0004 3 Solenoid valve 3 -N90-

Read measuring value block 6 006 1 Specified current of solenoid valve 4 -N91-
2 Specified current of solenoid valve 5 -N92-
0.747A 0.747A 0.747A 4 3 Specified current of solenoid valve 6 -N93-
1) Only for vehicles with CAN-bus. For information about which vehicles are equipped with CAN-bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00, engine codes, engine/transmission allocation,
ratios, equipment
2) Only for vehicles without CAN-bus. For information about which vehicles are equipped with CAN-bus
ratios, equipment
01-191

1234
2 Specified current of solenoid valve 7 -N94-
21.0 C 0.747A TC on 0 RPM 3 Torque converter clutch
4 Torque converter slip speed

Read measuring value block 8 008 1 Kick down switch
0%5% 3 Engine torque in Nm 1)
Throttle valve duty cycle in % 2)

4 Deceleration mode/engine under load
Read measuring value block 9 009 1) 1 Engine torque (actual)
2 Maximum torque
100 Nm 350 Nm 0 RPM 0% 3 Engine speed (RPM)
1) Only for vehicles with CAN-bus. For information about which vehicles are equipped with CAN-bus
ratios, equipment
2) Only for vehicles without CAN-bus. For information about which vehicles are equipped with CAN-bus
ratios, equipment
01-192

1234
Read measuring value block 9 009 2) 1 Engine torque (actual)
100 Nm 0 RPM 0 % 0.00 ms 3 Throttle valve value
4 Fuel consumption signal

Read measuring value block 10 010 1 Torque increase in torque converter
0,00 0 RPM 4 3 Gear selected
4 Anti-Slip Regulation (ASR)

Read measuring value block 11 011 1 Selector lever position
2 Tiptronic recognition
D M-switch up button Compr. ON 3 Tiptronic Switch -F189-
4 Air conditioning kick down
2) Only for vehicles without CAN-bus For information on which vehicles are equipped with CAN-bus
ratios, equipment
01-193
Notes:

log.
If specified values are not obtained in all display

fields:
- Press button.

Select function XX
01-194
Test table for transmissions with hydraulic control -E17-
Display Display Description Test requirements Spec. Value Corrective actions

group No. field on V.A.G
1551
display
001 1 Engine speed with engine running approx. - Perform electrical test page 01-
(RPM) 0...8200 273
RPM - Check identification of Transmission
Control Module (TCM) page 01-
273 , replace if necessary
- Check DTCs of Engine Controlk
Module (ECM) and if necessary check
identification
2 Sensor for while driving, with RPM - see DTC table, DTC number 17100 /
transmission RPM - gear selected1) P0716 page 01-45
G182-
R approx. 0...10
Continue 1M approx. 0...10
1) While driving, a second mechanic is required to read specifications.
01-195
Only for transmission with hydraulic control -E17-
Display Display Description Test Spec. value Corrective actions

group No. field requirements on V.A.G
1551
display
001 2 Sensor for 1 approx. - Perform electrical test page 01-273
Transmission RPM 0...10
-G182- With engine
under load
1 approx. - Read measuring value block, Display
0...300 group number 007 and determine which
In deceleration elements are faulty or not activated while
mode driving
2 approx.
0...4000 1)
3 approx.
0...8200 1)
4 approx.
0...8200 1)
Continue 5 approx.
0...8200 1)
1) Indication should mimic the current engine speed in display field 1, i.e. when engine speed increases or decreases,
transmission input RPM should increase or decrease.
01-196
Only for transmission with hydraulic control E17

1551
display
001 3 Transmission Vehicle While driving, with ... RPM 3) - See appropriate DTC for Transmission
Speed (VSS) sensor gear selected1) Vehicle Speed Sensor (VSS) -G38-
-G38- 2) (also called sensor for transmission
output RPM -G195-) 2)
R approx. - Perform electrical test page 01-273
0...2000
1M, 1 approx.
0...1200
2 approx.
0...4000
3 approx.
0...5800
4 approx. - Read measuring value block, display
0...8200 group number 007
Continue 5 approx. - Determine while driving which
0...8200 elements are faulty and which aren't
active
Notes and footnotes for display field 1 to 3 of display group number 001 are on the next page.
01-197
2) Also referred to as the sensor for transmission output RPM -G195-.
3)
Indication should mimic the engine speed in display field 1, i.e. when engine speed increases or decreases, transmission
RPM (output RPM) should increase or decrease.
Notes for display group number 001, display field 1 to 3;
Test conditions: Shifting process must be finished. Vehicle must not be in deceleration mode (no down-hill driving or
engine braking).
01-198
Display Display Description Test requirements Spec. value on Corrective actions

group No. field V.A.G 1551
display
001 4 Gear while Selector lever - Check solenoid valves. See
selected driving 1) position display group number 005 and
006
"N" "1"..."5" 2) - See DTC table, DTC numbers of
appropriate solenoid valves
"R" "R" - Check selector lever position.
Display group number 004
"D" "1" "2" "3" "4"
"5"
"4" "1" "2" "3" "4"
"3" "1" "2" "3"
"2" "1M" "2"
Notes and footnotes for display field 4 of display group number 001 are on the next page.
01-199
2)Transmission Control Module (TCM) is equipped with an automatic gear follower. The forward gear is indicated that the
TCM would activate in selector lever position "D".
Note on selected gear :
Faulty solenoid valves or other diagnostic malfunctions can prevent the selection of certain gears.
01-200
Display Display Description Test requirements Spec. Corrective actions

group field value on
No. V.A.G
1551
display
002 1 Dynamic code Under normal Min. value (very 0 Determined by driving style and
number (of dynamic driving economical) street conditions (acceleration,
shifting program) conditions 1) accelerator pedal movement,
speed and load)
Max. value High values move shift points
(very sporty) to higher engine speeds
240
Warm-up program is active
241
Anti-Slip Regulation (ASR) 242 Shifting avoided whenever
active possible
Tiptronic recognition activated - See appropriate DTCs for

Tiptronic Switch -F189-
243
Cruise control system 244 Only for USA, not applicable
characteristic map yet
01-201
Display Display Description Test requirements Spec. value Corrective actions

group field on V.A.G
No. 1551
display
002 2 Throttle valve value While idle 0...1 % When accelerating from idle to
standing Wide Open Throttle (WOT), %-
value increases steadily.
- Perform electrical test

page 01-273
Wide Open 99...100 %
Throttle - See respective DTCs of
(WOT) Throttle Position (TP) sensor -
G69-
3 Transmission Vehicle While driving 1) 0...8200 - See appropriate DTC for VSS
Speed (VSS) sensor -
-G38- (-G195-) 2)
G38- 2)
- See display group number
001
4 Gear selected See display group number 1, display field 4
2) Also referred to as sensor for transmission output RPM -G195-.
01-202

1551
display
003 1 Brake light switch Brake - See appropriate DTCs for brake
-F- light switch -F-
not -
operated
Brake Brake - Perform electrical test page
01-273
activated
2 Shift lock While brake not P N active - See appropriate DTC for shift
solenoid -N110- standing operated
2) lock solenoid -N110- 2)
brake - Check shift lock solenoid -N110-.

activated Perform electrical test page 01-
P N not 273
selected
3 Speed While driving 1) ...km/h Speedometer display and value on
V.A.G1551 may deviate slightly
from each other.
- If necessary, check Speedometer

Vehicle Speed sensor (VSS) -G22-
Continue
2) Shift lock solenoid -N110- is also referred to as shift lock solenoid -N110-.
01-203

number 1551
display
003 4 Supply voltage, While - Perform electrical test page 01-
terminal 15 standing 273
min. 10.0 V
max. 16.0 V - See DTC table, DTC 00532
page 01-45
004 1 ATF temperature While standing with ... C - Perform electrical test page 01-
engine running.
273
- See appropriate DTCs for
Transmission Fluid (ATF)
Temperature sensor -G93-
Continue
Notes for ATF temperature:
Recognized temperature of minus 50 C indicates a short circuit to Ground (GND)
Recognized temperature of minus 180 C indicates a short circuit to B+ or an open circuit
01-204

1551
display
004 2 Selector lever position - While P P - Check TR switch -F125-. Display
standing group no. 004
(Multi-function
Transmission Range
(TR) switch -F125-)
Selector R R - Perform electrical test page 01-
273
lever N N Check for agreement with indication in
instrument cluster
in D D
4 4
3 3 - If necessary adjust selector lever
bowden cable
2 2 Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37,
Continue shift mechanism, repairing
01-205

1551
display
004 3 Multi-function while Selector - See appropriate DTC for TR
Transmission Range standing lever
(TR) switch -F125- position L1 L2 L3 L4 switch -F125- 1)
P 1000 - Check TR switch -F125-

R 0100 - Perform electrical test page
01-273
N 1110
D 1011 - If necessary adjust selector
lever bowden cable
4 0111 Repair Manual, 5 Spd.
Automatic Transmission 01V,
Repair Group 37, shift
mechanism, repairing
Continue 3 0001
2 0010
01-206
Notes for display field 3 of display group number 004:
Input signals of Multi-function Transmission Range (TR) switch -F125- can be checked at the Transmission Control
Module (TCM).
Display field 3: (from left to right)

L1 L2 L3 L4
Wiring connection to TCM - Terminal 36 of - Terminal 8 of -J217- Terminal 37 of - Terminal 9 of -J217-
J217- J217- J217-
01-207
Display Display Description Test Spec. value on Corrective actions

group field requirements V.A.G 1551
number
display
004 4 Engine While driving 1) - See DTC table, DTC 00545, 18192
intervention and 18193 page 01-45
Engine speed
(ignition signal OK
without intervention)
CAN-bus
- Perform electrical test page 01-273

is - Check wire connection to Engine
Control Module (ECM)
switched on Engine interv.
is - - Only replace Transmission Control
Module (TCM) -J217- if necessary
switched off page 01-11
Notes for display field 4 of display group number 004 are on the next page:
01-208
This display field 4 is only valid for vehicles without CAN-bus, refer to next page for vehicles with CAN-bus. A)
Engine intervention is only activated during the shifting process. Depending on the driving situation, engine intervention
may only be activated briefly, i.e. the relatively slow data transfer to the V.A.G1551 can miss this brief engine intervention
under certain driving conditions.
A) There is a distinction made between vehicles with and without CAN-bus. For information on which vehicles are equipped
with CAN-bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00, engine codes, unit allocation, ratios, equipment
01-209
Display group Display Description Test Spec. value Corrective

number field requirements on actions
V.A.G 1551
display
004 4 Information of On Board While driving 1)
Diagnostic (OBD)
Indicated on display from left to

with right
CAN-bus
Malfunction display switched on 1
switched off 0
Trip completed 1
not completed 0 not applicable
Transmission warm-up completed 1
not completed 0
Engine start recognized 1
not recognized 0
Notes for display field 4 of display group number 004 see next page
01-210
This display field 4 is only valid for vehicles with CAN-bus, refer to previous display field 4 for vehicles without CAN-bus.
A)
with CAN-bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00, engine codes, aggregate allocation, ratios,
equipment
01-211

display
005 1 Solenoid valve 1 - while Gear - See appropriate DTC for
N88- 2) driving 1) selected
solenoid valve 1 -N88- 2)
R, 5, 2, 1, 1
1M
3, 4 0 - Perform electrical test
page 01-273
2 Solenoid valve 2 - while Gear - See appropriate DTC for

3, 2, 1 1
Continue R, 1M, 4, 5 0 - Perform electrical test
page 01-273
2) Solenoid valve 1 -N88- is also referred to as shift valve 1 solenoid valve 1 -N88-
01-212

display
005 3 Solenoid valve 3 - While Gear - See appropriate DTC for
3, 4, 5 X
R, 1, 1M, 2 0 - Perform electrical test
page 01-273
Un-switched solenoid valves are indicated with "0", switched solenoid valves are indicated with "1".
Variable switching solenoid valves are indicated with "X".
01-213

group No. field requirements V.A.G 1551
display
006 1 Specified current of solenoid While driving - See DTC table, DTC
valve 4 -N91- 2) 1)
00264 page 01-45
min. 0.1 A - Perform electrical test

page 01-273
max. 0.8 A
2 Specified current of solenoid While driving - See DTC table, DTC
valve 5 -N92- 3) 1)
266 page 01-45

page 01-273
Continue max. 0.8 A
2) Solenoid valve 4 -N91- is also referred to as pressure control valve 1 for auto. transmission -N215-.
01-214

group No. field requirements V.A.G 1551
display
006 3 Specified current of solenoid While driving - See DTC table, DTC
valve 6 -N93- 2) 1)
268 page 01-45

page 01-273
max. 0.8 A
Notes for specified current of solenoid valves:
Faulty solenoid valves or clutches or other malfunctions can prevent shifting into certain gears.
01-215
Display Display Description Test requirements Spec. Corrective actions

group field value on
No. V.A.G
1551
display
007 1 ATF temperature While standing with engine ... C - Check Transmission Fluid
running. When temperature (ATF) Temperature sensor -
sensor is faulty, a replacement
G93-; perform electrical test
value is transmitted.
page 01-273
2 Specified current While driving 1) min. 0.1 A - See DTC table, DTC 270
of solenoid valve 7 page 01-45
-N94- 2)
max 0.8 A - Perform electrical test
page 01-273
3 Torque converter While driving 1) TC open - See DTC table, DTC 1192
lock-up clutch
page 01-45
TC control - Perform electrical test

page 01-273
Continue TC closed
01-216

group field V.A.G 1551
No.
display
007 4 Torque hile TC open 0......standstill - See DTC table, DTC 00297,
converter slip driving RPM
1)
00660 and 01192 page 01-45
speed
TC control (last 20...120 RPM - Determine which element is

shift operation at faulty or not activated,
least 20 sec ago) transmission with shift elements
Repair Manual, 5 Spd.

Repair Group 37, transmission
with shift elements
TC closed 0...10 RPM - Check plausibility between
engine, transmission input- and
transmission speed; Display
group number 001
Notes for display field 4 of display group number 004 are on the next page:
01-217
Test requirements for torque converter slip speeds:
"TC closed": Shifting process must be complete (wait at least 1 sec.), the Torque Converter (TC) must be closed and the
accelerator pedal value must be constant.
"TC control": Indicated values are valid for the regulating condition of the throttle converter (control). Under inconvenient
conditions (e.g. accelerating on a hill), this condition is not reached until 20 seconds after the shifting process has been
completed. During this regulating phase, slip values of up to 350 RPM can be reached.
Excessive torque slip speeds can also indicate slipping clutches or non-activated shifting elements.
01-218

1551
display
008 1 Kick down Kick- - Check kick down switch, perform
switch -F8- down electrical test page 01-273
activated Kick down
not operated -
2 Throttle valve while idle 0...1 % When accelerating from idle to
value 1) standing Wide Open Throttle (WOT), %-
value increases steadily.
- Perform electrical test page

01-273
Throttle - See DTC table, DTC 00518 and
Continue (WOT) 00638 page 01-45
01-219

1551
display
008 3 3) Throttle valve While idle smaller than When accelerating from idle to Wide Open
duty cycle standing 30% Throttle (WOT), %-value increases
steadily.
without
CAN-
bus
- Perform electrical test page 01-273

Wide Open more than - See DTC table, DTC 00518 and 00638
Throttle 70% page 01-45
(WOT)
3 2) Engine torque While driving 1) Nm The signal for actual engine torque is
transmitted by the Engine Control Module
Continue (ECM) to the Transmission Control Module
(TCM) via the CAN-bus wiring.
with
CAN-
bus
Notes and footnotes for display group number 008 are on the next page.
01-220

group field V.A.G 1551
number
display
008 4 Signal for While Deceleration Deceleration For declines or delay
deceleration/engine under driving mode (engine brake)
load 1)
Engine is under load in

normal driving
Engine under - conditions.
load
2) Only for vehicles with CAN-bus For information on which vehicles are equipped with CAN-bus
3) Only for vehicles without CAN-bus For information on which vehicles are equipped with CAN-bus
01-221

number 1551
display
009 1 Engine torque while driving 1) ...Nm The signal for actual engine torque is
(actual) transmitted by the Engine Control Module
(ECM) to the Transmission Control Module
with
CAN-bus
2 Maximum while driving 1) ...Nm The engine torque required (reduced) by
torque the TCM during the shifting process 2)
3 Engine RPM with engine running approx. - See DTC table, DTC 529 and 543
0...8200 page 01-45
RPM
4 Throttle valve while Idle1) 0...1 % When accelerating from idle to WOT, %-
value standing value increases steadily.
- See DTC table, DTC 518 page 01-45

Throttle
(WOT)
Notes and footnotes for display group number 009 for vehicles with CAN-bus are on the next page.
01-222
2) While driving in one gear, the indicated shifting torque remains constantly high, since no torque reduction is required.
Notes for display group number 009;
This display group number 009 is only valid for vehicles with CAN-bus, refer to display group number 009 on next page for
vehicles without CAN-bus. A)
with CAN-bus
01-223

group field requirements on V.A.G
number 1551
display
009 1 Engine torque While driving 1) Nm Engine torque is calculated by the
(actual) Transmission Control Module (TCM) based
on fuel consumption signal and engine
speed signal.
without
CAN-bus
2 Engine RPM With engine approx.
- See DTC table, DTC 529 and 543
running 0...8200 page 01-45
RPM - Perform electrical test page 01-273
3 Throttle valve See display group number 2, display field 2

value
4 Fuel consumption While driving 1) ms Not applicable
signal (high time)
1) While driving a second mechanic is required to read specifications.
Notes for display group number 009 see next page;
01-224
This display group number 009 is only valid for vehicles without CAN-bus, refer to previous display group number 009 for
vehicles with CAN-bus. A)
For vehicles with motronic injection and ignition systems, engine torque is transmitted by the Engine Control Module
(ECM). For these vehicles, the fuel consumption display is omitted or always indicates "00ms".
with CAN-bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00, engine codes, aggregate allocation, ratios,
equipment
01-225

number 1551
display
010 1 Torque increase in While driving 1) 1...2,17 Calculated by the Transmission
torque converter Control Module (TCM) from the
torque converter slip speed
2 Engine speed With engine running approx. - Perform electrical test page 01-
(RPM) 0...8200 273
RPM - See DTC table, DTC 529 and 543
page 01-45

4 Anti-Slip Regulation While Only activated by the ASR control
(ASR) driving module when necessary
1) activated ASR active
not -
activated
01-226

number 1551
display
011 1 Selector lever See display group number 004, display field 2
position
2 Tiptronic Switch - Selector lever in tiptronic M switch - Perform electrical test from
F189- gate page 01-273
Selector lever not in -

tiptronic gate
3 Tiptronic Switch - Selector lever in tiptronic - Perform electrical test from
F189- gate, select gears
page 01-273
Shift up 3) Up switch
Shift down 2) Down switch

4 Air conditioning While A/C compressor switch-off is only
kick down driving 1) activated following kick-down for
activated Comp. OFF down-shift
not Comp. ON
activated
Notes and footnotes for display group number 11 are on the next page.
01-227
2)Operate down-switch (-) by shifting selector lever toward rear. For vehicles equipped with a tiptronic sport steering wheel,
down switch must also be operated by pressing the lower left or right button (-) on the steering wheel in order to check it's
function.
3)Operate up-switch (+) by shifting selector lever toward front. For vehicles equipped with a tiptronic sport steering wheel, up-
switch must also be operated by pressing the upper left or right button (+) on the steering wheel in order to check it's function.
Electronic Stabilization Program (ESP) Bosch 5.3 Page 1 of 27
01-217
Electronic Stabilization
Program (ESP) Bosch 5.3
The Electronic Stabilization Program (ESP) is a
driving dynamics regulation system. It stabilizes
the vehicle both in understeer and oversteer
situations.
ESP is an additional extension of the well-

known driving safety systems ABS/EDL and
ABS/EDL/ASR.
ESP increases the ability to control the vehicle

during critical driving situations. It reduces the
likelihood of skidding relative to the well-known
safety systems and improves steering control.
It can only function within physical limits.
01-218
ESP system sensors and components,

description
Control module for ABS with EDL/ASR/ESP -

J104-
The control module is combined with the

hydraulic unit as one unit. It controls the ESP,
ABS, EDL, ASR, EBD and ETR (Engine Torque
Reduction) functions. When ignition is switched
on, the control module performs a self-test. All
electrical connections are monitored constantly
and the solenoid valves are periodically checked
for function. If the control module fails entirely,
only the normal brake system will be available.
Steering angle sensor -G85-
The steering angle sensor is housed together

with the airbag spiral spring/return spring with
slip ring. It is located on the steering column
between the steering column switch and steering
wheel. It transmits the steering wheel's steering
angle to the ABS control module -J104 for
ABS/ASR/ESP via the CAN-bus. After replacing
the control module or the sensor, a zeroing must
be performed. For malfunctioning sensor, the
ESP function is not available.
01-219
Sensor for transverse acceleration -G200-
The sensor for transverse acceleration transmits

the values of lateral acceleration (cornering
force) to the ABS control module -J104 for
ABS/ASR/ESP. After replacing the control
module or the sensor, a zeroing must be
performed. For malfunctioning sensor, the ESP
function is not available.
Sender for rotation rate -G202-
The sender for rotation rate collects data, so-

called yaw moments or rotation rates, that
attempt to spin the vehicle on the vertical axis
and it sends these to control module -J104- for
ABS/ASR/ESP. For malfunctioning sensor, the
ESP function is not available.
Sender 1 for brake booster -G201-
The brake pedal position sensor recognizes the

current brake pressure in the brake circuit and
sends this data to the ABS control module
(w/EDL) -J104-. From this, the control module
calculates the wheel braking powers and
therefore the vertical forces affecting the vehicle.
If the sensor fails, the ESP function is not
available.
01-220
ASR/ESP button -E256-
The button enables the driver to switch off the

ESP function. By operating the brake pedal or by
pressing the button again, it is switched back on.
If re-activation is forgotten, the system
automatically reactivates itself once the vehicle is
restarted. The system cannot be switched off
when ESP is actively engaged and above a
specific speed.
Brake recognition switch (ESP) -F83-
The brake recognition switch (ESP) is also

identified as a release switch and it functions like
a pole-changing switch. When the driver brakes,
the switch changes from signal terminal 1 to
signal terminal 2. Since only one signal terminal
is ever closed, the system easily recognizes the
current condition and the release switch thereby
offers a high degree of personal safety.
Hydraulic pump for traction control -V156-
In order to generate the required admission

pressure on the intake side of the return flow
pump, an additional hydraulic pump is
necessary. Boost pressure is limited via a throttle
in the main cylinder, the hydraulic pump for
traction control -V156- itself is not regulated.
01-221
Examples:
During oversteering, the rear of the vehicle breaks out toward the outside
of the curve. The vehicle rotates more on its vertical axis than required to
maneuver through the curve. Braking the outside front wheel counters the
oversteering effect.
In understeering, it is the front of the vehicle that does not follow the
curve. The front of the vehicle breaks out. The vehicle rotates less on its
vertical axis than is required to maneuver through the curve. By braking
the rear inside wheel, the braking force generated intensifies the rotational
movement of the vehicle.
Component locations (except for new components) are the same as for
the Bosch 5.3 components. The procedures for removal and installation of
the components are found in:
01-222
Warning light functions, overview
If On Board Diagnostic (OBD) has detected a

malfunction in the system, it indicates the
malfunction by lighting up warning lamps when
ignition is switched on. The warning lamps are
located in the instrument cluster.
Instrument cluster without DIS
The illustration shows the ABS/EDL warning light -K47- (right arrow),
the warning light for brake system -K118- (center arrow, red symbol
for "brake system malfunction") and the traction control indicator light -
K86- (left arrow).
Instrument cluster with DIS
For DIS, there is no warning light for brake system -K118-. The red
"brake system malfunction" symbol appears in the display.
If the ABS/EDL warning light -K47 and the red symbol for "Brake
system malfunction" are not lit, but the brake system is not functioning
properly, check for malfunctions in the mechanical/hydraulic brake
system components.
01-223
"Brake ABS/EDL Traction control Possible reasons why the indicator lamps light up
malfunction" warning light indicator light
symbol
-K47- -K86-
off off off All indicator lights go out after the self-test (approximately three
seconds after the ignition is switched on). All systems are OK.
Pay attention to the notes on the next page
off off blinking ASR/ESP is in adjustment mode. The ASR/ESP indicator light
blinks approximately 3 times per second.
01-224
"Brake ABS/EDL Traction Possible reasons why the indicator lamps light up
malfunction" warning control
symbol light indicator
light
-K47-
-K86-
off on on A self-test is performed after the ignition is switched on. If all systems
are OK, warning lights, the ABS warning light -K47- and traction
control indicator light -K86- go out after approximately three seconds.
If the indicator lamps do not light up, check the relevant lamps carry
out "Electrical Test", steps 17 and 19. The possible causes are as
follows:
The battery voltage is insufficient. None of the lamps in the instrument

cluster light up. Check the battery.
Repair Manual, Electrical Equipment, Repair Group 90.
The ABS warning light -K47- does not light up during the self-test. There
is a short to Ground (GND) in the wiring that controls the ABS/EDL
warning light between terminal 32 of the ABS control module -J104- and
the instrument cluster. This malfunction does NOT influence the control
of the traction control indicator light.
The traction control indicator light -K86- does not light up during the self-
test; carry out "Electrical test", step 19.This malfunction does NOT
influence the control of the ABS warning light.
01-225
symbol light indicator light
-K47- -K86-
off off off There is an irregularity. The indicator lamps go on during the self-
test and then go out. The possible causes are as follows:
The voltage supply for the ABS control module -J104- is between
7 and 10 volts and the vehicle speed is < 6 km/h. Carry out
"Electrical test", step 21.
The DTC "01119 gear recognition signal" is stored in the DTC
memory. Check DTC memory page 01-356 .
The signal indicating whether the parking brake is set or released
is not being sent to the ABS control module -J104-. "Read
measuring value block" function 08 page 01-256 , display group
2 page 01-261 .
Check the brake light switch -F-. "Read measuring value block"
function 08 page 01-256 , display group 2 page 01-261 .
Check the zero position of the steering angle sensor -G85-. "Read
measuring value block" function 08 page 01-256 , display group
5 page 01-270 .
01-226
light
-K47-
-K86-
off on on The indicator lights did not go out after the self-test. However, the red
"brake system malfunction" symbol did not go on. The On Board
Diagnostic recognized a malfunction, which deactivated the
ABS/EDL/ASR/ESP. However, the "Electronic Brake Distribution" (EBD)
remained activated. Check DTC memory page 01-356 .
The ESP driving test may have been activated page 01-250
Check the voltage supply for the red "brake system malfunction" symbol.
Carry out "Electrical test", step 18. If the control is malfunctioning, see
the next example for lighted indicator lights.
During the last drive, a dynamic malfunction of the wheel speed sensor
occurred or a malfunction in the ABS return flow pump -V39- occurred.
In this case, the indicator lights automatically go off after the vehicle is
started, and has exceeded a speed of 2.75 km/h or a check of the return
flow pump indicated it is OK.
Also observe notes on the next page.
01-227
light
-K47-
-K86-
off on on Continuation from preceding page.
A DTC is stored in the DTC memory the first time the vehicle exceeds 6
km/h, if the voltage supply to the ABS control module -J104- is between
7 and 10 volts and the indicator lights go on. If during the drive, the
voltage supply to the ABS control module -J104- exceeds 10 volts, the
indicator light go out. The DTC remains in the memory. "Check DTC
memory" page 01-356 .
off on off
The ESP driving test was not completed; page 01-250
01-228
light
-K47-
-K86-
on on on The ABS and traction control indicator lights go on, and three seconds after
the ignition is switched on the red "brake system malfunction" symbol goes
on.
A malfunction deactivated the ABS/EDL, ASR/ESP and the "Electronic

Brake Distribution" (EBD).Check DTC memory page 01-356 .
WARNING!
The brake system is only partially functional. Because brake pressure at

the rear wheels is no longer regulated vie Electronic Brake Distribution
(EBD), the rear wheels can lock even during light braking (excessive
braking at rear axle). This can cause the rear of the vehicle to break
loose and thereby cause and accident.
Note: For vehicles with automatic transmission, the red "brake system
malfunction" symbol does not appear immediately after the ignition is
switched on. Instead, the note "Depress brake pedal before engaging gear"
appears in the display. Press the brake pedal and select a gear. The red
brake warning light appears, if the light control is working properly.
01-229
-K47- -K86-
off off on The traction control indicator light does not turn off after the self-
test.
There is a malfunction that only affects the traction control. The

ABS/EDL and EBD systems are not deactivated. Check DTC
memory page 01-356 .
Traction control has been switched off using the traction control
button. If the traction control indicator light does not light up in this
case, check the switch and the indicator light, carry out the
"Electrical test", steps 19 and 20.
Short circuit to B+ in the ASR/ESP button: The traction control
indicator light goes out five minutes after the ignition is switched on.
Carry out "electrical test", step 20.
There is a short to Ground (GND) in the wiring that controls the
traction control indicator light between terminal 31 of the ABS
control module -J104- and the instrument cluster. Carry out
"electrical test", step 19.
01-230
-K47- -K86-
on on off No DTCs are stored in DTC memory. The ABS and traction control
warning lights do not go out after the self-test, and three seconds
after the ignition is switched on the red "brake system malfunction"
symbol goes on.
There is an open circuit or short circuit to B+ in the wiring that
controls the traction control indicator light between terminal 32 of
the ABS control module -J104- and the instrument cluster; carry
out "Electrical test" step 17.
Voltage supply for control module less than 7 volts; carry out
"Electrical test" step 21.
on off off No DTCs are stored in DTC memory. The red "brake system
malfunction" symbol remains lit after the ignition is switched on.
The brake fluid level is too low

Malfunction in instrument cluster: Carry out "Electrical test", step
18.
01-231
Check Control Module Version (function

01)

and select the address word 03 "Brake
Electronics".
Note:
The following explanation of how to perform On

Board Diagnostic (OBD) is based on use of the
VAG1551 scan tool. Performing On Board
Diagnostic (OBD) using the VAS5051 tester is
similar.
- Advance through program sequence by pressing

the button.
01-232

Select function XX
- Press buttons -0- and -1- to select "Check Control Module Version" 01.
Press -Q- button to confirm input.
Note:
For allocation of ABS control module -J104-, also refer to parts
catalog.
8D0 907 389E 1) ABS/ESP AWD 2) D01 3) Indicated on display:

Coding 06397 WSC xxxxx
Index 1): ABS control module Part. No. including control module index
Index 2): Indicates system identification.
Index 3): Indicates hardware and software status
01-233
Control module versions
System identification Prod. Control Index Coding Data CAN terminal resistance
No.: 1) module part transmission in control module:
no.: via:
All Wheel Drive (AWD); 1AT: 4B0 907 389 - coding not CAN-bus 120
ABS/ESP possible
Front Wheel Drive 1AT: 8D0 907 389 - Can be CAN-bus 120
(FWD); ABS/ESP coded
All Wheel Drive (AWD); 1AT: 8D0 907 389 A Can be CAN-bus 120
ABS/ESP coded
Front Wheel Drive 1AT: 8D0 907 389 D Can be CAN-bus 2600
(FWD); ABS/ESP coded
All Wheel Drive (AWD); 1AT: 8D0 907 389 E Can be CAN-bus 2600
ABS/ESP coded
01-234
Code Control Module (function 07)
After installing a new ABS control module

(w/EDL) -J104- or a new steering angle sensor
-G85-, the ESP system must be coded again.
After the coding, the steering angle sensor
must be calibrated.
The coding of the ESP control module is used for

adaptation of the control module to the vehicle.
Coding is only possible if a dealership number is

stored in the VAG1551 scan tool.
Note:
If the control module is coded with code 00000 or

with a code that does not match the vehicle, the
ABS warning light -K47- and the traction control
indicator light -K86- remain continuously lit, and
the DTC 01044 - Control module incorrectly
coded - is stored in DTC memory of the control
module.
Before the control module can be coded, "Login

Procedure" function 11 must be successfully
carried out using the VAG1551/1552 scan tool.
01-235
To perform the login procedure and the coding,

the brake caliper type must be determined (see
the following illustrations).
Front brake caliper type
- Illustration shows the brake type FN3 made by Teves/Ate (recognized

by: clip on brake pad carrier).
01-236
- Illustration shows the brake type HP2 made by Lucas (recognized by:
dual piston housing).
01-237
Performing login

Electronics".

Select function XX
- Press the -1- button twice to select the function "login procedure".

11 - Login procedure
Login procedure Q Indicated on display:

Enter code numbers XXXXX
- Enter code according to the following table and press -Q- button to
confirm input.
01-238
Login code table ESP
Engine type Transmission type Brake caliper type (front) Login code
4 cylinder gas engine Manual transmission Lucas C54 09675
4 cylinder gas engine Manual transmission FN3 Teves/ATE 09575
4 cylinder gas engine Automatic transmission Lucas C54 09677
4 cylinder gas engine Automatic transmission FN3 Teves/ATE 09577
6 cylinder gas engine Manual transmission FN 2/ HP2 dual-piston brake caliper 09495
6 cylinder gas engine Automatic transmission HP2 double-piston brake caliper 09497
4 cylinder diesel engine Manual transmission Lucas C54 09655
4/6 cylinder diesel engine Manual transmission FN3 Teves/ATE 09555
4 cylinder diesel engine Automatic transmission Lucas C54 09677
4/6 cylinder diesel engine Automatic transmission FN3 Teves/ATE 09557
01-239
Code control module
- Check the control module version and press the

button.

Select function XX
- Press buttons -0- and -7- to select "Code control module" function 03.

07 - Code control module

Enter code number XXXXX
- Enter code according to the following table and press -Q- button to
confirm input.
01-240
Code table ESP
Engine type Transmission type Brake caliper type (front) Code

4 cylinder gas engine Manual transmission Lucas C54 04175
4 cylinder gas engine Automatic transmission Lucas C54 04177
6 cylinder gas engine Manual transmission FN 2/ HP2 dual-piston brake caliper 04395
6 cylinder gas engine Automatic transmission HP2 double-piston brake caliper 04397
4 cylinder diesel engine Manual transmission Lucas C54 04155
4/6 cylinder diesel engine Manual transmission FN3 Teves/ATE 04255
4 cylinder diesel engine Automatic transmission Lucas C54 04177
4/6 cylinder diesel engine Automatic transmission FN3 Teves/ATE 04257
01-241
8D0 407 389D ABS/ESP front D16

VAG1551 scan tool display indicates control module coding, e.g.: 8D0
407 389D ABS/ESP front.
Coding 06255 WSC XXXXX
- Press button.
Read Measuring Value Block (scan tool function 08) for transmissions with hydraulic control -E18/2- Page 1 of 42
01-228

(scan tool function 08) for
transmissions with hydraulic
control -E18/2-
Notes:
For transmissions with hydraulic control -E17-,

"Read Measuring Value Block" can be found
page 01-187
CAUTION!
To avoid risk of accidents during measuring

and test drives, note safety precautions
page 01-34 .
Procedure

tool and select Transmission Control Module
(TCM) using "address word" 02 page 01-36 .
Ignition must remain switched on for this

procedure.

Select function XX
- Press PRINT button to turn on Scan Tool (ST) printer. Indicator lamp in
button must light up.
01-229
Read measuring value block Q When indicated on display:

- Enter desired display group number page 01-230 display group
overview.
Read measuring value block 1 Indicated on display (example) for display group 001:
1234
Notes:
Explanation of values in individual display fields test table page 01-
234 .
Display can be printed out when printer is switched on.
Display group V.A.G 1551 VAS5051 tester

- If specified values are obtained in all display fields, press button.

Select function XX
01-230
Overview of selectable display group numbers for transmission with hydraulic control -E18/2-

1234
Read measuring value block 1 001 1 Engine speed (RPM)
2 Sensor for transmission RPM -G182-
0 RPM 0 RPM 0 RPM 4 3 Sensor for transmission output RPM -G195-
4 Gear selected
Read measuring value block 2 002 1 Actual program
2 Throttle valve value or accelerator pedal position
DS 0 % 0 RPM 4 3 Sensor for transmission output RPM -G195-
4 Gear selected
Read measuring value block 3 003 1 Brake light switch
2 "P" "N" lock
PN active 0 km/h 12.8 V 3 Speed
4 Voltage supply
2 Selector lever position
21.0 C P 1000 0101 3 Multi-function switch position
4 Information of On Board Diagnostic (OBD)
01-231
(example)
Display fields: Display group Display Description
no. field
1234
Read measuring value block 005 1 Solenoid valve 1 -N88-

5

0004
4 Gear selected
Read measuring value block 006 1 Specified current of Pressure Control Valve 1 for auto.
6 transmission -N215-
Specified current of Pressure Control Valve 2 for auto.

2 transmission -N216-
0.747 A 0.747 A 0.747 A 0
Specified current of Pressure Control Valve 3 for auto.
transmission -N217-
3
not applicable
4
Read measuring value block 007 1 ATF temperature
7
2 Specified current of Pressure Control Valve 4 for auto.

transmission -N218-
21.0 C 0.747 A TC on 0
RPM Torque converter lock-up clutch
3
Torque converter slip speed
4
Read measuring value block 008 1 Kick down switch
8
2 Throttle valve value or accelerator pedal position
3 Deceleration mode/engine under load

0 % Deceleration
4
01-232

1234
Read measuring value block 9 009 1 Engine torque (actual)
100 Nm 0 RPM 0 % 3 Throttle valve value or accelerator pedal position
4
Read measuring value block 10 010 1 Torque increase in torque converter
0.00 0 RPM 4 3 Gear selected
4
Read measuring value block 11 011 1 Selector lever position
2 Tiptronic recognition
D M-switch up-switch 3 Tiptronic Switch -F189-
Read measuring value block 12 012 1 Type of drive, load
2 Dynamic code number
E 56 80 45 3 Drive resistance index
4 Driver evaluation
Read measuring value block 125 125 1 Reception of engine messages via CAN-bus
2 Reception of ABS messages via CAN-bus
10 3
01-233
Notes:

the display will be printed out .
If specified values are not obtained in all display

fields:
- Press button.

Select function XX
01-234
Test table for transmissions with hydraulic control -E18/2-

group field requirements on V.A.G1551
number
display
001 1 Engine RPM With engine approx. - See DTC table, DTC 17968 / P1560
running 0...8200 page 01-45
RPM
2 Sensor for While driving, with RPM - See DTC table, DTC number 17100 /
transmission RPM gear selected1) P0716 page 01-45
-G182-
R approx.
0...8200
1. 1m approx. - Read measuring value block, display
0...2000 group number 006 or 007 and
determine which elements are faulty or
not activated while driving
Continue 2 approx.
0...8200
3 approx.
0...8200
01-235

group field V.A.G1551
number
display
001 2 While With gear RPM - See previous page
driving1) selected
4 approx.
0...8200
5 approx.
0...8200
3 Sensor for While driving, with gear RPM - See DTC table, DTC
transmission output selected1) number 17105 / P0721
RPM -G195- page 01-45
R approx.
0...2000
1. 1m approx. - Read measuring value
0...2000 block, display group number
006 or 007
Continued 2 approx. - Determine while driving
0...4000 which elements are faulty
and which aren't active
3 approx.
0...5800
01-236
Display group Display Description Test Spec. value on Corrective actions

number field requirements V.A.G1551
display
Continued 4 approx. 0...8200
5 approx. 0...8200
Test conditions: Shifting process must be finished. Vehicle must not be in deceleration mode (no decline driving or engine
brake).
01-237
Display Display Description Test requirements Specification for Corrective actions

group field display on
number V.A.G1551
001 4 Gear While Selector - Check solenoid valves. See
selected driving1) lever display group numbers 005,
position 006 and 007
"N" "1"..."5"2) - See DTC table, DTC of
respective solenoid valves
page 01-45
"R" "R" - Check selector lever
position. Display group
number 004
"D" "1m" "2" "3" "4" "5"
"4" "1m" "2" "3" "4"
"3" "1m" "2" "3"
"2" "1m" "2"
2)Transmission Control Module (TCM) is equipped with an automatic gear follower. The forward gear is indicated that the
TCM would activate in selector lever position "D".
Faulty solenoid valves or other DTCs can prevent the selection of certain gears.
01-238

number
display
002 1 Actual In normal driving Determined by driving style and street
program conditions 1) conditions (acceleration, accelerator
pedal movement, speed and load)
Dynamic shift Shifting avoided whenever possible

program is active
DS
Warm-up program Up-shifting occurs faster to avoid high
is active RPM.
WL
Anti-Slip Regulation - Check display group number 004
(ASR) active
AS
Continue Tiptronic recognition - See DTC table, DTC 18141/P1733 to
activated 18152/P1744 page 01-45
TT
01-239

group field on V.A.G1551
number
display
002 2 Throttle valve value or While Idle 0...1 % When accelerating from idle
value from accelerator standing to Wide Open Throttle
pedal position (WOT), %-value increases
steadily.

page 01-273
Throttle - See DTC table, DTC
(WOT) 18269 / P1861 page 01-
45
3 Sensor for transmission While driving 1) 0...8200 - See DTC table, DTC
output RPM -G195- number 17105 / P0721
page 01-45
- See display group number
001
01-240

number
display
003 1 Brake light activated Brake - See DTC table, DTC 17087 /
switch -F- P0703 page 01-45

page 01-273
not -
activated
2 Shift lock While Brake not P N active - See DTC table, DTC
solenoid -N110- standing in operated 18170/P1762 and 18196 /
P, N P1761 page 01-45
- Check shift lock solenoid -

N110-. Perform electrical test
Continue Brake P N not page 01-273
activated selected
01-241

group field requirements V.A.G1551
number
display
003 3 Speed While driving 1) km/h - If necessary, check speedometer
vehicle speed sensor (VSS) -G22-
4 Supply voltage, While - Perform electrical test page
terminal 15 standing 01-273
min. 10.0 V
max. 16.0 V - See DTC table, DTC
18158/P1750 and 18159 / P1751
page 01-45
Note for display field 3, speed:
Display of the speedometer and values at VAS 5051 or V.A.G 1551 may deviate slightly from each other.
01-242

number
display
004 1 ATF While standing with C - Perform electrical test page 01-273
temperature engine running
- See DTC table, DTCs 17094 / P0710,
17095 / P0711, 17096 / P0712 and
17097 / P0713 page 01-45
Continue
Notes for ATF temperature:
Temperature of minus 50 C indicates a short circuit to Ground (GND),
Temperature of minus 180 C indicates a short circuit to B+ or an open circuit,
01-243

number
display
004 2 Selector lever position While P P
standing
(Multi-function Transmission
Range (TR) switch -F125-
Selector R R
lever N N Check for agreement with
indication in instrument
cluster
in D D
- Check display field 3
4 4
3 3
2 2
Continue
01-244

group field on
number V.A.G1551
display
004 2 1) Selector lever While P Z1 - Check multi-function Transmission
position - standing, and Range (TR) switch -F125-. display
selector lever R group number 004, display field 3
(Multi-function between
Transmission Range or
(TR) switch -F125-)
R
and
D
Between positions at N Z2 - Perform electrical test page 01-
selector lever and 273
mechanism D
D Z3 - If necessary adjust selector lever

and bowden cable
4
4 Z4 Repair Manual, 5 Spd. Automatic
and Transmission 01V, Repair Group 37,
Continue 3 shift mechanism, repairing, selector
lever cable, checking and adjusting
or
3
and
1) This display field is not displayed until model year 2000 (May 1999)
Note on in-between positions:
When the selector lever is shifted into one of the in-between positions, the Scan Tool indicates "Z1", "Z2", "Z3" or "Z4".
Display in instrument cluster must not indicate a gear selected, i.e. PRND432 is indicated without any particular gear
highlighted.
01-245

group field on V.A.G1551
number
display
004 3 Multi-function While Selector - See DTC table, DTC 17090 /
Transmission Range standing lever P0706 page 01-45
(TR) switch -F125- position L1 L2 L3 L4
P 1000 - Check multi-function
Transmission Range (TR)
switch -F125-
R 0100 - Perform electrical test page
01-273
N 1110
D 1011 - If necessary adjust selector
lever bowden cable
4 0111 Repair Manual, 5 Spd.
Repair Group 37, shift
mechanism, repairing
Continue 3 0001
2 0010
01-246
The input signals of the Multi-function Transmission Range (TR) switch -F125- can be checked at the Transmission
Control Module (TCM).
Display field 3: (from left to right)

L1 L2 L3 L4
Wiring connection to Transmission Control Module Terminal 36 of - Terminal 8 Terminal 37 of - Terminal 9
(TCM) -J217- J217- of J217- of
-J217- -J217-
01-247
Display group Display Description Test Spec, value on Corrective

number field requirements V.A.G1551 actions
display
004 4 Information of On Board While driving 1)
Diagnostic (OBD)
Indicated on display from left

to right
Malfunction display Switched on 1
Switched off 0
Trip Completed 1
Not completed 0 Not applicable
Transmission warm-up Completed 1
Not completed 0
Engine start Recognized 1
Not 0
recognized
01-248

number
display
005 1 Solenoid valve While Gear selected - Check whether display
1 -N88- driving1) is the same as on shift
lever display
R. N, D, (1 and 2 (1 X
gear), Shift-down from
5 to 4 gear
D (3 and 4 gear) 0 - Perform electrical test
page 01-273
2 Solenoid valve While Gear selected
2 -N89- driving1)
Continue N, D (1, 2 and 3 X - Perform electrical test

gear) page 01-273
R, D (4 and 5 gear) D, 0
down-shift 5 to 4
Unswitched solenoid valves (inactive) are indicated with "0", switched solenoid valves (active) are indicated with "1".
01-249

number
display
005 3 Solenoid valve While Gear selected - See DTC table, DTC
3 -N90- driving1) 17145/P0761, 17146/P0762 and
17147/P0763 page 01-45
D (down-shift 5 X
to 4 gear)
D (3, 4. and 5 x or 0 2) - Perform electrical test page
gear) 01-273
R, N, D (1 and 0
2 gear) 2 (1
gear)
2)The solenoid valve is switched momentarily while driving, meaning that the mode changes from display "0" to "X" and then
again to "0". This switching in these gears is not relevant.
Unswitched solenoid valves (inactive) are indicated with "0", switched solenoid valves (active) are indicated with "1".
01-250

number
display
006 1 Specified current of Pressure While - See DTC table, DTC
Control Valve 1 for auto. driving1) 18222/P1814 and 18223 /
transmission -N215- P1815 page 01-45
page 01-273
max. 2.0 A
2 Specified current of Pressure While - See DTC table, DTC
page 01-273
Continue max. 2.0 A
01-251

number
display
006 3 Specified current of Pressure While - See DTC table, DTC
page 01-273
max. 2.0 A
4 Not yet applicable
Notes for specified current of solenoid valves:
Faulty solenoid valves or pressure control valves or clutches or other malfunctions can prevent shifting into a specific
gear.
01-252

number
display
007 1 ATF temperature See display group number 1, display field 4
2 Specified current of Pressure While min. 0.0 A - See DTC table, DTC
max 2.0 A - Perform electrical test
page 01-273
3 Torque converter (TC) lock- While TC open - See DTC table, DTC
up clutch driving1) 17125 / P0741 page 01-
45
Continue TC control - Perform electrical test
page 01-273
TC closed
01-253

number
display
007 4 Torque While TC open 0......standstill - Check ATF oil level
converter (TC) driving1) RPM
slip speed
Repair Manual, 5 Spd.
Repair Group 37,
- See DTC table, DTC number

17105 / P0721 and 17125/P0741
page 01-45
TC control 20...120 RPM - Determine which element is
faulty or not activated,
(last shift transmission with shift elements
process at
least 20
seconds ago) Repair Manual, 5 Spd.
Repair Group 37,
TC closed 0...20 RPM - Check plausibility between
engine RPM, transmission input
RPM and transmission RPM,
display group number 001
Note:
Test requirements for torque converter slip speeds next page
01-254
Test requirements for torque converter slip speeds:
"TC closed": Shifting process must be complete (wait at least 1 sec.), the Torque Converter (TC) must be closed and the
accelerator pedal value must be constant.
"TC control": Indicated values are valid for the "regulating condition" of the throttle converter (control). Under inconvenient
conditions (e.g. accelerating on a hill), this condition is not reached until 20 seconds after the shifting process has been
completed. During this regulating phase, slip values of up to 350 RPM can be reached.
Excessive torque slip speeds can also indicate slipping clutches or non-activated shifting elements.
01-255

number
display
008 1 Kick down switch -F8- Kick- - Check kick-down
down switch, perform
operated 2) Kick-down electrical test page
01-273
not operated -
2 Throttle valve value or While idle 0...1 % When accelerating from
value from accelerator standing idle to Wide Open
pedal position Throttle (WOT), %-value
increases steadily.
- See DTC table, DTC

18269 / P1861 page
Wide Open 99...100 % 01-45
Throttle
(WOT) - See also display group
number 002, display
field 2
3 Signal for While Deceleration Deceleration For down-hill or delay
deceleration/engine under driving1) mode (engine braking)
load
Engine is under load
during normal driving
Engine under - conditions.
load
2)Operate kick-down means that the accelerator pedal needs to be depressed to stop. Display must simultaneously indicate
"100%" in display field 2.
01-256

display
009 1 Engine torque While driving 1) Nm
2)
- See DTC table, DTC 18265 /
P1857 page 01-45
2 Engine RPM With engine approx. 0...8200 - See DTC table, DTC 17968 /
running P1560 page 01-45
Continue RPM
2) While driving in one gear, the indicated shift torque remains constantly high, since no engine torque reduction is required.
The signal for actual engine torque is transmitted by the Engine Control Module (ECM) to the Transmission Control Module
01-257

number
display
009 3 Throttle valve value or While idle 0...1 % When accelerating from idle
value from accelerator standing to Wide Open Throttle (WOT),
pedal position %-value increases steadily.
- See DTC table, DTC

18269 / P1861 page 01-
Wide Open 99...100 % 45
Throttle
(WOT) - See also display group
number 002, display field 2
4 2) Transmission input While Nm Should be like display field 1.

torque driving1)
01-258

number
display
010 1 Torque increase in While driving 1) 0...3.2 Calculated by the Transmission
torque converter Control Module (TCM) from the
torque converter slip speed
2 Engine speed With engine approx. 0...8200 - See DTC table, DTC 17968 /
(RPM) running P1560 page 01-45
RPM
4 2) Vehicle acceleration While Min. -10 m/s2

(actual) driving1)
01-259
Display group Display Description Test requirements Spec. value on Corrective actions
number field V.A.G1551
display
011 1 Selector lever See display group number 4, display field 2
position
2 Tiptronic Switch - Selector lever in tiptronic M-shift - Perform electrical test
F189- gate page 01-273
Selector lever not in -
tiptronic gate
3 Tiptronic Switch - Selector lever in tiptronic - Perform electrical test
F189- gate, select gears page 01-273
(up/down shift)
Shift up 1) Up-shift
Shift down 2) Down-shift
1)Operate up-shift (+) by shifting selector lever toward front. For vehicles equipped with a tiptronic sport steering wheel, up-
shift must also be operated by pressing the upper left or right button (+) on the steering wheel.
2)Operate down-shift (-) by shifting selector lever toward rear. For vehicles equipped with a tiptronic sport steering wheel,
down-shift must also be operated by pressing the lower left or right button (-) on the steering wheel.
01-260
Display group Display Description Test requirements Spec. value on Corrective

number field V.A.G1551 actions
display
012 1 Type of drive, Driving without load, e.g. driving on E
load flat surface
Driving under load, e.g. uphill B
driving
2 Dynamic code Calculated from drive resistance 0...256 not yet
number index and driver evaluation applicable
3 Necessary for calculation of 0...256

dynamic code number
Drive resistance
index
4 Driver evaluation Necessary for calculation of 0...256
dynamic code number
01-261

number
display
013 1) 1 CAN-bus While standing with Nm

normalizing torque ignition switched on
2 CAN-bus engine 0 ... 63 - See DTC table, DTC
code 18157/P1749 and 18249 /
P1841 page 01-45
3 CAN-bus 1 - Check coding of Engine
Transmission Control Module (ECM)
code
4 CAN-bus software 0 ... 63 - See DTC table, DTC 18263 /
version code P1855 page 01-45
1) This display group number is not displayed until model year 2000 (May 1999)
Display field 2 and 4: When replacing the ECM, the same indication that appeared for the old control module should
appear after installation. If this is not the case, the wrong ECM was installed, or it is wrongly coded.
01-262

display
125 1 Reception of an engine While driving 1) 1 - See DTC table, DTC
message via the CAN-bus 18258 / P1850 page
Received 01-45
Not received 0 2) - Perform electrical test
page 01-273
2 Reception of an ABS While driving 1) 1 - See DTC table, DTC

message via the CAN-bus 18259 / P1851 page
Received 01-45
Not received 0 2) - Perform electrical test
page 01-273
2) If "0" is shown and there are no DTCs stored in memory, the relevant control module is not CAN capable (or is faulty).
Basic setting (scan tool function 04) Page 1 of 64
01-242
Basic setting (scan tool

function 04)
Initiating "Basic Setting" function 04 does the
following for ESP:
The steering angle sensor -G85- is zeroed

using display group 001 page 01-243
Before you can zero the sensor, you must have

successfully carried out the "Login Procedure"
function 11 using the VAG1551/1552 scan tool
and the ABS control module -J104- must be
coded page 01-234 .
The hydraulic pump for traction control -

V156- is activated using display group 002
Activation of the hydraulic pump for traction

control -V156- does not require any preparations.
It is used to bleed the hydraulic system page
01-248 .
The ESP driving test is activated using

display group 003
The ESP driving test is used to test the

plausibility of the signals from the sensor for
transverse acceleration, yaw sensor and
pressure sensor page 01-250 .
01-243
Steering angle sensor -G85-, zeroing

procedure
- Now it is necessary to perform the zeroing

procedure on the steering angle sensor -G85-.
- To initialize the steering angle sensor, turn the

steering angle at least 10 degrees in either
direction
- Move steering to zero position, maximum

tolerance is 5 degrees.
01-244
Note:
The diagnostic must not be exited and ignition

must not be switched off between the procedures
"Code control module" and "Steering angle
sensor calibration". Otherwise, the entire
procedure must be repeated.

Select function XX
- Press the -1- button twice to select the function "login procedure".

11 - Login procedure
Login procedure Q Indicated on display:

Enter code numbers XXXXX
- Select code number 40168. Press -Q- button to confirm input.

Select function XX
- Press buttons -0- and -4- to select function 04 "Basic Setting"
01-245

04 - Basic Setting
Basic Setting Q Indicated on display:

- Press buttons -0-, -0-, and -1-. Press -Q- button to confirm input.
Function is unknown or can If this appears in display, you have not successfully carried out the "Login
not be performed at the moment.
Procedure".
System in basic setting 1

Calibrating steer. sens. OK
- Check the zero position using "Read measuring value block" function
08, display group 5.
or:
01-246

Calibrating steer. sens. not OK
- Check DTC Memory
- Erase DTC Memory
- Then repeat zeroing.
- Advance through program sequence by pressing the button.

Select function XX
or:
01-247

Calibrating steer. sens. locked
Steering wheel was not initialized, i.e. the steering wheel must be turned
at least 10 degrees in either direction.

- Then repeat zeroing.
- Advance through program sequence by pressing the button.

Select function XX
01-248
Hydraulic system, bleeding
The hydraulic pump for traction control -V156- is

activated to bleed the hydraulic system.
Repair manual, Brake System, Repair Group

47

Electronics".

Select function XX

04 - Basic Setting
01-249


Vent system OK
Note:
The hydraulic pump for traction control -V156- is activated for ten (10)
seconds.
- Press the button to end the function.

Select function XX
01-250
ESP driving and system test
The ESP driving test is used to test the

plausibility of the signals from the sensor for
transverse acceleration, yaw sensor, and
pressure sensor.
Road test vehicle
Some DTCs are only recognized by the On

Board Diagnostic (OBD)while the vehicle is
moving. You can check the entire system during
a road test. During road test, drive at a speed of
at least 60 km/h for 30 seconds. Check traffic
conditions and perform an ABS regulated braking
when appropriate. You will feel a pulsing in the
brake pedal indicating the system is active.
Note:
Once the ESP driving test has been initiated, it

cannot be aborted and must be performed
completely. After exiting the diagnostic, the
ABS/EDL and ASR/ESP lamps remain switched
on in order to indicate that the test is active and
that system function is not available yet.
Warning, ABS and ESP not functioning!
01-251
WARNING!
While system is in diagnostic, the

ABS/ESP/EBD is not active. Driving the
vehicle after On Board Diagnostic (OBD) has
detected a malfunction presents the risk of
accident. The brake system will only be
partially functional. Because brake pressure
at the rear wheels is no longer regulated vie
Electronic Brake Distribution (EBD), the rear
wheels tend to brake excessively. This
causes the rear of the vehicle to break loose.
When the use of test equipment is required

during road tests, test equipment must
always be secured to the rear seat and
operated from there by a second person. If
test and measuring equipment is operated
from the passenger seat, the person seated
there could be injured in the event of an
accident involving deployment of the
passenger-side airbag.
01-252

Electronics" page 01-4

Select function XX

04 - Basic Setting


System test activated OK
The ESP driving test is activated.
The ABS warning light -K47- and the traction control indicator light -
K86- go on.
01-253
- Press buttons -0- and -6- to select "End Output"

function 06. Press -Q- button to confirm input.

Select function XX
- Disconnect VAG 1551 scan tool.
- Start engine.
- Press the brake pedal hard (brake pressure higher than 35 bar) until
the traction control indicator light -K86- turns off.
Note:
This completes the adjustment with the engine not running
- Perform the following road test:
WARNING!
Always follow the rules of the road and pay attention to traffic
conditions as your first priority.
01-254
Make a right or left turn. Then reverse the

direction and continue driving until the
ABS/EDL lamp turns off.
Note:
While driving around the curves, a yaw rate of

around 10 /sec must be obtained. A curve with
a radius of 10 to 12 m and a speed of 15 to 20
km/h for around 4 sec. fulfills this requirement.
The ABS warning light -K47- must go out. This

completes the ESP driving test and the system
is OK.
If the ABS/ESP warning light -K47- remains lit,

the test is not OK (system locked). Check DTC
memory.
01-255
If the ABS warning light -K47- does not go out,

the ESP driving test was not performed properly.
If the ABS warning light -K47- does not go out,

and the traction control indicator light -K86-
lights up again, there are malfunctions in the
system; Check DTC memory page 01-356
Note:
If the ESP driving test was interrupted, e.g.: by

switching off the ignition, the entire test must be
repeated.
01-256
Read Measuring Value Block (function

08)
The control module can transmit measured

values to the VAS5051 tester and VAG1551
Scan Tool (ST). These measured values provide
information about the operational status of the
system and the sensors connected to it. In many
cases the data supplied can be used to
troubleshoot and repair malfunctions. The
measured values provided by ESP are contained
in six display groups, which can be accessed via
their display group numbers.
- Connect the VAS5051 tester or VAG1551 Scan

Tool (ST) and select the address word 03 "Brake
Electronics".
01-257
Notes:

log.
When reading the measuring value block, also

check wiring and connectors for loose
terminals.


Select function XX
function 08.

Read measuring value block HELP Indicated on display:

01-258
Notes:
Display fields 1 through 4 show the current wheel circumference speeds in km/h. These are calculated by the ABS control
module -J104- on the basis of the signals received from the wheel speed sensors. If one of the display fields shows no
reading, proceed as for DTCs 00283, 00285, 00287, 00290 "ABS Wheel Speed Sensor" DTC table page 01-357 .
In order to check whether wheel speed sensors are properly allocated to each wheel, the vehicle must be raised. On
vehicles with manual transmission put the gear shift lever in neutral. On vehicles with automatic transmission move the
selector lever to position "N". Turn appropriate wheel by hand. Remaining drive wheels must be secured against turning.
When a vehicle is accelerated uniformly on a dry surface, the displayed value will increase continuously by whole
numbers; e.g. 6 km/h, 7 km/h, 8 km/h ... . The difference between displayed values 1-4 should not be more than 1 km/h
(error from out-of-round wheels). If the values jump, for instance from ...6km/h, 7 km/h, to 12 km/h...or if the difference
between the displayed values is greater than 1 km/h, then check the installation of the wheel speed sensors and rotors.
01-259

1 to 19 1) 1 to 19 1) 1 to 19 1) 1 to 19 1)
km/h km/h km/h km/h

Rear right wheel circumference speed
Rear left wheel circumference speed
Front right wheel circumference speed
Front left wheel circumference speed
1)OBD is terminated by ABS control module -J104- if road speed exceeds 19 km/h (12 mph). 1 km/h is the minimum speed
that can be displayed (at 0 km/h, for example, the tester displays 1 km/h).
01-260
Note:

on the VAG1552 mobile scan tool or the arrow
buttons and on the screen of the VAS5051
tester.

manually.
Read measuring value block Indicated on display:

01-261

0 or 0 or 0 or 0 or
operated operated operated operated

Traction control button
0 Traction control button not operated

Traction control switch operated
- Check traction control button if there are deviations. Carry out "Electrical test", step 20.
Parking brake - Check parking brake warning light switch -F9- if
there are deviations. Carry out "Electrical test", step
0 Parking brake not engaged 27.
Parking brake engaged
Brake light switch: - Check brake light switch if there are deviations. DTC table page
01-356 ; DTC "Brake light switch -F-"; DTC 00526.
0 Brake pedal not depressed
Brake pedal depressed
Brake test switch: - The brake test signal precedes the brake light signal. Check brake light switch if there
are deviations:DTC table page 01-356 ; DTC "Brake light switch -F-"; DTC 00526.
0 Brake pedal not
depressed
Brake pedal depressed
01-262
Note:

tester.

manually.

01-263
Note:
To read the display fields for engine speed and

current engine torque with the engine running,
communication between the scan tool and the
control module must be terminated via the "End
Output" function page 01-16 . Start the
engine and reinitiate communication between
the scan tool and the control module.

function 08.

01-264
Read measuring value 3 Indicated on display

block
60 to 0 to 0 to 0 to 100
8000 630 630
%
1 RPM Nm Nm
Throttle valve angle:
- If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the
malfunction with the help of the DTC table page 01-356 .
Dissipation torque:
- If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the
malfunction with the help of the DTC table page 01-356 .
Engine torque:
- If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the malfunction with
the help of the DTC table page 01-356 .
Engine speed:
Engine speed is displayed in increments of 60 RPM, starting at 60 RPM.

- If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the malfunction with the help
of the DTC table page 01-356 .
Notes:
On Board Diagnostic (OBD) will be terminated by the ABS control module -J104- if road speed exceeds 19 km/h.
The actual engine speed (MMI) is calculated by subtracting the dissipation torque from the engine torque.
01-265
Note:

tester.

manually.

01-266
Note:
For test table display group 4:
Display group 4 is not occupied for control

modules with no. 4B0 907 389 without index
and cannot be selected for these control
modules by pressing buttons <-1 and 3-> on the
VAG1551 or by pressing the arrow buttons
and on the VAG1552 or via manual input.
If an attempt is made to select display group

number 4:
Function is unknown or can Indicated on display:

- Press button.

Select function XX
Bypass display group number 4 or you will be forced to exit the "Read
measuring value block" function. Press the C-button to do this and then
select display group number 3 or 5 directly.
01-267

00:00 h Off/on not not
or used used
invalid
EDL shut-off
Electronic Differential Lock (EDL) is deactivated at excessive brake temperature (only EDL).
Standing time (TIM):
The standing time (TIM) is used to calculate how much the brakes have cooled while the ignition is off. The ABS control
module -J104- receives the standing time signal from the instrument cluster.
- If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the malfunction with the help
of the DTC table page 01-356 .
Invalid:
Battery disconnected or completely discharged

Open circuit in wire from ABS control module (w/EDL) -J104- to instrument cluster
Note:
01-268
Note:

tester.

manually.

01-269
Note:
To read the display fields for yaw rate and

transverse acceleration while driving,
communication between the scan tool and the
control module must be terminated via the "End
Output" function page 01-16 . Start the
engine and reinitiate communication between
the scan tool and the control module.

function 08.

01-270

block
- 720 - 69 - 41 - 25 m/s2 ...
... /s ... bar ...
+ 25 m/s2
+720 + 69 /s +292
bar
Transverse acceleration:
Specification with vehicle at standstill: 0....0.7 m/s2

Specification with steering wheel fully turned at a speed of 20 km/h: max. 6.0 m/s2; the
value of the measured value increases steadily.
Another test for the sensor is located page 01-271 ; Fig. 1.
Brake pressure:
Specification with brake pedal not depressed: 0....5 bar

Rotation rate:
Specification with vehicle at standstill: 3 /s

Specification with steering wheel fully turned at a vehicle speed of 20 km/h: max. 65 /s; the value of the
measured value increases steadily.
Steering angle:
Specified value when driving straight ahead (steering wheel in straight-ahead position) 5 .1)
1) If the steering angle sensor is OK, there will be an indication, even if the zeroing procedure was not performed.
Note:
If nothing is displayed, press -C- button, select function 02 and check DTC memory. Repair the malfunction with the
help of the DTC table page 01-356 .
01-271
Note:
The transverse acceleration sensor is very

impact-sensitive, as is the combined sensor for
yaw rate and transverse acceleration. If one of
these sensors is dropped, do not reinstall it in
vehicle under ANY circumstances. Instead, use a
new sensor.
Fig. 1 Sensor for transverse acceleration -G200-

In order to test the sensor, or the combined sensor for yaw rate and
transverse acceleration, the sensor must be removed. Remove rear
seat bench. Unscrew control module for ultra-sound sensors -J347-
and then the sensor. Leave the sensor connected and turn it 90
relative to installation position along its longitudinal axis.
01-272
After this, a value of either - 9,8 1 m/s2 or

+ 9,8 1 m/s2 will be indicated on the scan
tool display in display group 5 (use the "Read
measuring value block" function).
A plus in front of the number indicates the

affect on the sensor while driving around a
left-hand curve.
A minus in front of the number indicates the

affect on the sensor while driving around a
right-hand curve.
After reinstalling the sensor for transverse

acceleration -G200- or the combined sensor
for yaw rate and transverse acceleration,
tighten the mounting bolts to 5 Nm. Tighten
the mounting bolts for the control module for
ultra-sound sensors -J347- to 2 Nm.
Note:
Due to an error in the test card 8.0 for the

VAG1551 scan tool and the test card 5.0 for the
VAG1552 scan tool, the display for Measuring
Value Block 5, display group 4 is offset by one
decimal point. This means, for example, that a
transverse acceleration value of 9.81m/s2 is
displayed simply as 0.98 m/s2 .
01-273
Note:

tester.

manually.

01-274

block
0 volts to 18 on on 0 ...
volts or or
131071
off off
Workshop code:
The workshop code indicates the last workshop that executed the "Login Procedure" (function
11) under address word 03, "Brake electronics" page 01-237 .
If no code is displayed, the "Login Procedure" under address word 03 "Brake Electronics" has
not been carried out yet.
Voltage at motor for ABS return flow pump:
off specified value, there is no voltage at the motor for the ABS return flow pump.
on not permitted during "Read measuring value block", there is voltage at the motor for the ABS
return flow pump.
- Carry out "Electrical test", steps 12, 23 and 24.
ABS solenoid valve relay:
on specified value, relay was activated by ABS control module -J104- during ignition on.
off not permitted during "Read measuring value block", the relay was not activated during "ignition on".
- Carry out "Electrical test", steps 11 and 22.
Supply voltage for ABS control module -J104- at terminal 1:
Specification: 10.5 - 14.5 V

- If specified value is not obtained, carry out "Electrical test", step 21.
01-275
Note:

tester.

manually.

- Press buttons 1-, 2- and -5-.
01-276
Note:
For test table display group 125:
Display group 125 is not occupied for control

modules with no. 4B0 907 389 and cannot be
selected for these control modules by pressing
buttons <-1 and 3-> on the VAG1551 or by
pressing the arrow buttons and on the
VAG1552 or via manual input.
If an attempt is made to select display group

number 125 despite this:
Function is unknown or can Indicated on display:

- Press button.

Select function XX
01-277

Steering angle Engine Transmission not
0 or 1 0 or 1 used
0 or 1
Transmission Control Module (TCM): (only for vehicles with automatic transmission)
0: No information received from the Transmission Control Module (TCM) via the CAN-bus.
1: Information is being received from the Transmission Control Module (TCM) via the CAN-
bus.
Engine Control Module (ECM):
0: No information received from the Engine Control Module (ECM) via the CAN-bus.
1: Information is being received from the Engine Control Module (ECM) via the CAN-bus.
Steering angle sensor:
0: No information received from the steering angle sensor via the CAN-bus.1)
1: Information is being received from the steering angle sensor via the CAN-bus.
1) If the steering angle sensor is OK, it sends information, even if the zeroing procedure was not performed.
Note:
01-278

(function 03)
Output Diagnostic Test Mode (DTM) is used to

check the function of actuators. Actuators are
also called actors. These are components that
the control module activates when it reacts to the
signals sent by sensors, e.g. solenoid valves,
relays and pump motors.
Note:
Output Diagnostic Test Mode (DTM) only

functions on vehicles containing control
modules with no. 8D0 407 389 A/D/E.
For control modules with no. 4B0 907 389,

output Diagnostic Test Mode (DTM) is not
possible.
Output Diagnostic Test Mode (DTM) can and

must only be selected once after the ignition
is switched on.
01-279
"Function of actuators" includes all functions and

properties of an actuator under operating
conditions. This means, for example:
An electrically operated hydraulic valves that

opens and closes when activated by the control
module.
The relay of an electrical motor when activated

by the control module. The motor switches on
and carry outs the task.
Before initiating the output Diagnostic Test Mode

(DTM), make sure there are no electrical
malfunctions in the system you wish to test. This
will enable you to recognize any mechanical
problems. Perform a guided troubleshooting
before starting output Diagnostic Test Mode
(DTM) page 01-19 .
01-280
Are you sure there are no electrical malfunctions

in the system? If you have made sure that there
are no electrical malfunctions in the system, you
will be able to identify any mechanical
malfunctions in the individual actuators if the
results of the output DTM are not as specified
here. Replace the relevant part.
With the Bosch 5.3 ABS/ESP the output

Diagnostic Test Mode (DTM) enables you to
check the electrically actuated hydraulic valves
and the pump motor in the hydraulic module. You
can also check that the brake lines going to the
four wheels are connected correctly.
01-281
Notes:
The vehicle must be raised until all wheels are

free to turn. Ask a colleague to help. The
colleague will have to check the wheels to
determine whether they turn freely.
You can stop the test sequence at any time by

pressing the -C- button.
To avoid overloading the components being

checked, they are actuated during the test
sequence for a period of 60 (or 90) seconds.
The actuator test will be terminated if the "
button" is not pressed within this period.
The ABS warning light and the red "brake

system malfunction" symbol blink during the
test.
Pressing the brake pedal repeatedly this

relieves the vacuum in the brake booster. For
this reason, the brake pedal must be pressed
harder in order to achieve the same braking
effect. Your work will be easier if you run the
engine briefly. This will build up vacuum in the
brake booster again.
01-282
During the test, the individual test steps are

shown in the second line of the VAG1551 scan
tool display. The following abbreviations are
used.
IV = Inlet valve
OV = Outlet valve
LF = Left Front
RF = Right Front
LR = Left Rear
RR = Right Rear
B+ = Battery Positive Voltage (B+) at valve
0V = 0 volts; No voltage at valve
Locked/free = Wheel condition; must be checked

by second technician
Hydr-P = Hydraulic pump
01-283

Electronics".


Select function XX
(DTM)" function 03.

03 - Output Diagnostic Test Mode (DTM)
01-284

ABS hydraulic pump -V64-
ABS hydraulic pump -V64- must start running. This is audible.
When you put your foot on the brake pedal you can feel it vibrating. The
brake pedal vibrates because the hydraulic pump generates pressure
pulses in the brake lines. The pressure pulses generate oscillations.
These are directed to the brake pedal and make it vibrate.
The pressure pulses in the brake lines are not sufficient to lock the
wheels.
01-285
The hydraulic circuit diagram shows a systematic representation of

an ABS/EDL system. This will give a better understanding of the
various test steps in the output Diagnostic Test Mode (DTM).
shaded components are in action.

Thin solid lines represent hydraulic lines or hoses that are not under
pressure.
Thick broken lines represent hydraulic lines or hoses working as
suction lines.
Thick solid lines represent hydraulic lines or hoses that are under
pressure.
- Press button.
01-286

Operate brake
- Press button.

When you press the brake pedal, brake fluid pressure will be built up in all
four calipers. All four wheels lock.
Requirement for this: mechanical/hydraulic components of the brake

system must be fully functional. This means that the master brake cylinder
is able to build up pressure in all wheel cylinders and the hydraulic
connections and lines are all sealed properly.
01-287
If the wheels do not lock, visually inspect brake fluid reservoir, master
brake cylinder, hydraulic unit, and calipers.
Concentrate on the left-front wheel first. The function of the control

elements for this wheel is tested first.
Note:
"pressure build-up" phase during ABS-controlled braking.
- Press button.
01-288

Ifl: B+ Ofl: 0V fl wheel locked
- Keep pressing brake pedal.
Inlet valve is activated. It interrupts the brake line. However, fluid pressure
is still maintained in the wheel cylinder. The left-front wheel remains
locked.
Note:
"maintain pressure" phase during ABS-controlled braking.
- Press button.
01-289

Ifl: B+ Ofl: B+ fl wheel free
Keep pressing brake pedal. The inlet valve and the outlet valve for the
left-front wheel are activated. The hydraulic pump starts running and
reduces the fluid pressure in the caliper via the open outlet valve.
The brake pedal must not give, and should press harder against your
foot.
You should now be able to turn the left-front wheel.
01-290
If you cannot turn the wheel, check whether the

brake line for the left-front wheels is connected
correctly.
If yes, this indicates a mechanical malfunction in one of the valves,

If the pedal gives under your foot, this means that the inlet valve or the
check valve activated in parallel to the inlet valve is leaking. Replace
hydraulic unit.
Note:
"pressure reduction" phase during ABS-controlled braking.
- Press button.
01-291

Ifl: B+ Ofl: 0V fl wheel free
- Keep pressing brake pedal. Only the inlet valve is still activated and
interrupts the brake line. If the inlet valve is not leaking, you should be
able to turn the left-front wheel.
If you cannot turn the wheel, this means that the inlet valve or the check
valve activated in parallel to the inlet valve is leaking. Replace hydraulic
control unit.
- Press button.
01-292

- Keep pressing brake pedal. Inlet valve is no longer being activated. It is

no longer interrupting the brake line. The brake pedal will give
perceptibly under your foot. Fluid pressure is built again in the left-front
caliper. The wheel will be locked.
- Press button.
01-293

Release brake
- Press button.
Continue output Diagnostic Test Mode (DTM) in order to check the

front right, rear left, and rear right wheels in sequence. The test
steps indicate the procedure for the front left wheel. They will
therefore not be repeated in detail.
01-294

Operate brake
- Press button.

- Press button.

Ifr: B+ Ofr: 0V fr wheel locked
- Press button.
ABS hydraulic pump -V64- must start running.

Ifr: B+ Ofr: B+ fr wheel free
- Press button.
01-295

Ifr: B+ Ofr: 0V fr wheel free
- Press button.

- Press button.

Release brake
- Press button.

Operate brake
- Press button.

- Press button.
01-296

Irl B+ Orl: 0V rl wheel locked
- Press button.

Irl B+ Orl: B+ rl wheel free
- Press button.

Irl B+ Orl: 0V rl wheel free
- Press button.

- Press button.
01-297

Release brake
- Press button.

Operate brake
- Press button.

- Press button.

Irr: B+ Orr: 0V rr wheel locked
- Press button.
01-298

- Press button.

Irr: B+ Orr: 0V rr wheel free
- Press button.

- Press button.

Release brake
- Press button.
01-299

The EDL change-over valve (left) and the EDL inlet valve are activated.
ABS return flow pump -V39- runs for one second. It draws brake fluid from
the brake fluid expansion tank via the EDL inlet valve. The hydraulic pump
builds brake fluid pressure in the EDL regulated wheel cylinders. These
wheels will then be locked.
If not, this indicates a mechanical malfunction in one of the valves,

- Press button.
01-300

End
Note:
The output diagnostic test mode is completed. The ABS/EDL warning light
and the red warning symbol for brake system go out.
- Press button.

Select function XX
Note:
If the ABS/EDL warning light does not go out, this indicates a
malfunction in the system. Observe test sequence exactly page 01-
17 .
CAN-bus, function Page 1 of 10
01-263
CAN-bus, function
Bus:
The term "bus" refers to a system that transports

and distributes data.
CAN:
The Controller Area Network is a bus system that

uses two wires. These are called bus wires. Data
is transferred to the connected control modules
serial (one after the other) across the bus wires.
These control modules communicate with each

other via the CAN-bus.
Overview of power train data-BUS
1 - Transmission Control Module (TCM) -J217-

2 - Driver for BUS
3 - Motronic Engine Control Module (ECM) -J220-
4 - Driver for BUS
5 - Termination resistance
01-264
6 - Power train data-BUS (CAN-bus, twisted 2 line wire)

7 - Termination resistance
8 - Driver for BUS
9 - ABS Control Module -J104-
01-265
Two-wire bus system, checking
If the DTC table indicates to check the bus:
- Use the applicable wiring diagram, determine

how many control modules communicate with
each other via the bus.
- Press the -0- button twice to select the function

"Automatic test sequence".
- Before checking the bus wires, make sure that

none of the control modules connected are
malfunctioning.
A malfunction will disrupt communication to

other control modules.
Is there a malfunction?
- Fix the malfunction before proceeding.
- Note malfunction and erase DTC memory of all

control modules Checking and erasing DTC
memory of the relevant control module.
01-266
- Press buttons -0- and -6- to select "End Output"

function 06. Press -Q- button to confirm input.
- End output of scan tool by selecting the function

"end output" page 01-42 .
- Refer to the DTC table in the applicable repair

manual for help in repairing the malfunction.
When necessary repairs have made:
- Check bus wires if communication to the control

modules is still faulty. If yes, check bus wires.
There can be two situations:
Two control modules communicate via a "two-

line bus system"
Three or more control modules communicate

via a "two-line bus system"
01-267
Two control modules communicate via a

"two-line bus system"
- Disconnect both control modules.

- Check bus wires for open circuit.
- Check whether there is a short circuit between bus wires.
01-268
- Check bus wires for short circuit to B+ or Ground (GND).
If there are no malfunctions in the bus wires:
- As a test, replace one of the control modules. Select a control module

that will take the least amount of time to replace and cost the least
amount of money.
- If communication between the control modules across the bus is still
interrupted, replace the second control module.
01-269
Three or more control modules are

communicating across a "two-line bus
system"
- Analyze DTCs stored in the memories of the

control modules.
Example 1:
From the DTCs stored in the memories, determined that control module 1
is not communicating with control modules 2 and 3.
Control module DTCs stored in DTC memories:

1
Missing signal from control module 2
2
3

- Disconnect the control modules connected across the bus wires and
check bus wires for open circuit.
- Replace control module 1 if bus wires are OK.
01-270
Example 2:
From the DTCs stored in the memories, determined that control module 2
is not communicating with control modules 1 and 3.
Control module DTCs stored in DTC memories:

1
2
3

check bus wires for open circuit.
- Replace control module 2 if bus wires are OK.
01-271
Example 3:
Using DTCs stored in the memories, determined

that none of the control modules are sending or
receiving signals.
Control DTCs stored in DTC

module memories:
1
Hardware faulty
2
Hardware faulty
3
Hardware faulty
check for a short circuit between the bus wires.
- Check bus wires for short circuit to B+ or Ground (GND).
01-272
- If there are no malfunctions found in the bus

wires, check whether one of the control modules
is responsible for a short circuit of the bus wires
to each other, to B+ or to Ground (GND).
Disconnect each of the control modules

connected via the bus wires one at a time and
check whether the malfunction "Hardware faulty"
has been eliminated.
If it was eliminated, replace the control module

that is currently disconnected. If malfunction was
not eliminated, re-connect that control module
and disconnect the next control module
connected via the bus wires.
Electrical testing Page 1 of 66
01-273
Electrical testing
Special tools and test equipment:
VAG1526A multimeter
VAG1598/20 test box
VAG1594A connector test kit
01-274
Repair Manual, 5 Spd. Automatic Transmission

01V,

Component Locations"
Notes:
Use VAG1526A multimeter for the test. The

tables list which measures range needs to be
selected before taking each measurement.
The specified values are valid for an ambient

temperature of 0 to 40 C (32 to 104 F).
If the values obtained differ from the specified

values, determine the malfunction using the
applicable wiring diagram.
If the measured values only deviate slightly

from the specified values clean sockets and
connectors of testers and repeat test. Before
replacing a component, check wires and
connections. If the specified values are below
10 , repeat the resistance measurement on
the component.
Use VAG1598/20 adapter to connect test

equipment.
01-275
The contact numbers of the connector and the

socket numbers of VAG 1598/20 test box match
up page 01-277 .
To check the multi-function switch, it is not

necessary to connect test box VAG 1598/20
because first the connectors for the multi-
function switch are checked.
CAUTION!
To avoid permanent damage of electronic

components, select the appropriate
measuring range on tester before connecting
the measuring leads.
Test requirements
Battery voltage OK
Fuses for Transmission Control Module

(TCM) OK

Component Locations
Fuses for component being tested OK. The

fuse holder is behind a cover on the side of
the instrument cluster.
Ground (GND) connections OK:
Check battery Ground (GND) strap and Ground

(GND) strap between body and transmission.
Check Ground (GND) connections for

Transmission Control Module (TCM).

Component Locations
01-276
- For all test steps, switch ignition off, disconnect multi-pin connector for
Transmission Control Module (TCM) -J217- (located in front of
passenger seat under carpet in foot well page 01-11 ) and connect
VAG1598/20 adapter to wiring harness connector.
- If measuring values do not match specifications, follow instructions in
right-hand column of test table (labelled "Corrective action") page
01-11 .
- Always perform all steps indicated in the "Corrective action" column.
- Only perform test steps recommended in the DTC table (selective
troubleshooting).
01-277
88-pin connector for Transmission Control Module (TCM) -J217- (sockets on VAG1598/20)
1- Solenoid valve 5 -N92- 18- Kick-down switch -F8- (not for E-gas and V6-TDI)
2- Shift lock solenoid -N110- 19- Control input to transmission from ABS control module
3- Vacant 20- Engine intervention (via ignition timing) 1)
4- Solenoid valve 7 -N94- 21- ATF temperature sensor -G93-
5- Solenoid valve 4 -N91- 22- ATF temperature sensor -G93-
6- Ground (GND) for power consumers, term. 23- Sensor for transmission RPM -G182- (shielding)
31
7- Vacant 24- Vacant
8- Multi-function TR switch -F125-, L2 25- Selector lever display (not for Highline combi)
9- Multi-function TR switch -F125-, L4 26- Supply voltage (terminal 30) with or without fuses depending on
model wiring diagram
supply voltage for cruise control system
10- Brake light switch -F- (not for E-gas and 27- Kick-down for air conditioning 1)
V6-TDI)
11- Vacant 28- Ground (GND) for electronics (terminal 31)4)
12- Vacant 29- Solenoid valve 6 -N93-
13- Tiptronic recognition 30- Solenoid valve 1 -N88-
14- Transmission VSS -G38- 31- Vacant
15- Transmission VSS -G38- (shielding) 32- Solenoid valve 3 -N90-
16- Sensor for transmission RPM -G182- 33- Solenoid valve 2 -N89-
17- Signal for malfunction monitor (OBD II - 34- Ground (GND) for power consumers (terminal 31)
request) 1) 2)
01-278
35- Fuel consumption signal 54- Supply voltage (terminal 15)
(engine torque, actual) 1)

36- Multi-function TR switch -F125-, L1 55- Supply voltage (terminal 15)
37- Multi-function TR switch -F125-, L3 56- Vacant
38- Vacant -
39- Vacant -
40- Engine speed (RPM) signal 1) -
41- Throttle position value (load signal) 1) -
42- Transmission VSS -G38- -

43- Vacant -
44- Sensor for transmission RPM -G182- - Terminals 57 - 83 are vacant
45- Vacant -
46- Tiptronic upshift switch -
47- Tiptronic downshift switch -
48- Vacant -
49- Vacant 84- Vacant
50- Vacant 85- CAN-bus 3)
51- Upshift/downshift signal 86- CAN-bus 3)
(for engine torque reduction)
52- Supply voltage for solenoid valves 87- Vacant

53- Supply voltage for solenoid valves 88- K-wire for On Board Diagnostic (OBD)
01-279
1) Only for vehicles without a CAN-bus.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00; Code letters, engine/transmission applications,
ratios, equipment
2) Signal is transmitted to Transmission Control Module (TCM) via the Engine Control Module (ECM) and can only be checked
in read measured value block page 01-186 .
3) Only for vehicles with a CAN-bus. Further information for CAN-BUS on the CAN-bus page 01-263
ratios, equipment
4) Pin 28 at the control module is vacant for vehicles with 10-pin connector of multi-function switch -F125-.
01-280
List of test steps (88-pin connector)
Only perform test steps for the relevant component, as listed in DTC and Read Measuring Value Block tables.
Item checked Item checked

Supply voltage for TCM -J217- Solenoid valve 5 -N92- (Pressure control
- Perform test - Perform test steps 13
valve -2- -N216-)
steps 1 and 7 and 8
Shift lock solenoid -N110- Solenoid valve 6 -N93- (pressure control
- Perform steps 2, - Perform test steps 14
valve -3- -N217-)
6 and 16 and 8.
Brake light switch -F- Solenoid valve 7 -N94- (pressure control
- Perform test - Perform test steps 15
valve -4- -N218-)
step 3. and 8.
Supply voltage for cruise Transmission VSS -G38- (Sensor for

- Perform test - Perform test step 18.
control system transmission output RPM -G195-)
step 4.
Kick-down switch -F8- Sensor for transmission RPM -G182-

- Perform test - Perform test step 19.
steps 5 and 17
(not for E-gas)
Multi-function TR switch ATF temperature sensor -G93-
- page 01-322 - Perform test step 20.
(driving range sensor) -F125-
Solenoid valve 1 -N88- - Perform test Wiring connection to ECM1) - Perform test steps 21,
steps 8 and 9 22, 23, 24, and 25
1)Signal is transmitted to Transmission Control Module (TCM) via the Engine Control Module (ECM). Test is only for vehicles
without CAN-bus.
01-281
Item checked Item checked

Solenoid valve 2 -N89- Tiptronic switch -
- Perform test steps - Perform test steps 26 and 27
F189-
10 and 8
Solenoid valve 3 -N90- - Perform test steps CAN-bus 2) - Perform test step 28 and check CAN-bus
11 and 8 system page 01-265 .
Solenoid valve 4 -N91- - Perform test steps
12 and 8
(Pressure control valve -1-
-N215-)
2) Only for vehicles with CAN-bus
ratios, equipment
ratios, equipment
01-282
Electrical test table
Voltage measurement: Switch multimeter to 20 V measuring range

step conditions
1598/20 value
- Additional
sockets steps
1 55 + 6 Supply voltage for approx.battery
Ignition - Check wiring per wiring
Transmission Control Module voltage
switched on diagram.
55 + 6 (TCM) -J217-
- Check wiring from terminals 6,
54 + 28 34 and 28 to Ground
1)
- Check wiring from terminals 54
and 55 to terminal 15 of central
electric.
54 + 55 0V
26 + 6 Voltage of electr. system approx. battery
(term. 30) for TCM -J217- switched off voltage diagram.
26 + 34
2 2+6 Shift lock solenoid -N110- 2) Ignition approx. battery - Check wiring per wiring
voltage
switched on diagram.
- Test multi-function TR switch -
F125- for short circuit.
- Test shift lock solenoid -N110-
for short circuit.
- Perform test steps 6 and 16
2) Solenoid for shift lock -N110- is also referred to as shift lock solenoid -N110-
01-283
Voltage measurement: switch multimeter to 20 V measuring range

Test conditions
1598/20 - Additional steps value
sockets
3 1) 10 + 6 Brake light switch

Ignition switched less than 1 V - Check wiring per wiring
on diagram.
10 + -F-
282) Brake pedal not - Replace and adjust brake
depressed light switch -F-.
not for E-gas approx. battery Repair Manual, Brake
- Brake pedal
engines voltage System, Repair Group 47
depressed
4 9+6 Supply voltage for approx. battery - Check wiring from terminals
Ignition switched
Cruise Control, Control voltage
on 6 and 28 to Ground.
9 + 282) Module
Selector lever in - Check wiring from terminal 9
-J213- D, 4 and 3 to terminal 15 of central
electrics.
- Check wiring to cruise
control, control module -J213-
- Check multi-function switch -
F125- page 01-322
less than 5 V - Check fuse 31
Selector lever in
P, R, N, and 2
1) This test cannot be performed on vehicles with E-gas. The signal is transmitted from brake light switch or brake test switch
to Engine Control Module (ECM). The ECM then forwards the signal to the Transmission Control Module via the CAN-Bus.
01-284

Test conditions
sockets
5 1) 18 + 54 Kick-down
Ignition switched on
approx. battery - Check wiring per wiring
switch -F8- voltage diagram.
not for E-gas - Depress accelerator to
engines kick-down - Adjust or replace accelerator
pedal cable.
Repair Manual, General,

Engine, Repair Group 20
- Perform test step 17.
1)This test cannot be performed on vehicles with E-gas. The kick-down switch -F8- in this case is integrated in the Throttle
Position (TP) Sensor (-G79-, -G185-).
01-285

Test conditions
step
sockets
6 2 + 54 Shift Lock Solenoid - 14 to 28
Ignition switched - Check wiring per wiring diagram.
N110- 1) off
2 +55 - Check multi-function switch -F125-
Page 01-306
- Check Shift Lock Solenoid -N110- for
short circuit
- Perform test steps 2 and 16.
01-286
Resistance measurement: switch multimeter to 200 measuring range

step conditions
1598/20 value
- Additional
sockets steps
7 6 + 34 Ground (GND) connection of smaller than
Transmission Control Module 1
switched off diagram.
28 1) + 34 (TCM) -J217-
34 + battery smaller than

ground (GND) 1
8 52 + 53 Voltage supply to solenoid smaller than
valves switched off 1,5 diagram.
- Perform test step 1
- Check wiring between TCM
and 16-pin connector page
01-302 .
- Check harness in
transmission according to
wiring diagram
01-287

step conditions
1598/20 value
- Additional steps
sockets
9 52 + 30 Solenoid Valve 25 to 35
Ignition - Check 16-pin connector to transmission for
1 -N88- switched off contact corrosion
30 + 34 infinity - Perform test step 8
1)
10 52 + 33 Solenoid Valve 25 to 35 - Check wiring connection from 88-pin connector to

Ignition
2 -N89- 8-pin connector page 01-302
switched off
33 + 34 infinity - Check wiring harness in transmission according
1)
to wiring diagram, replace if necessary.
11 52 + 32 Solenoid Valve 25 to 35 - Remove and install valve body
Ignition
3 -N90- switched off
01V, Repair Group 38
32 + 34 infinity
1)
12 52 + 5 Solenoid Valve 6 to 8
Ignition
4 -N91- switched off
5 + 34 infinity
1)
1) Adjust VAG 1526 to highest resistance ( ) range
01-288

step conditions
1598/20 value
- Additional steps
sockets
13 52 + 1 Solenoid valve 5 6-8
Ignition - Check for contact corrosion on 16-pin connector
-N92- 2) switched off to transmission.
1 + 34 infinite - Perform test step 8.
1)
14 52 + 29 Solenoid valve 6 6-8 - Check wiring between 88-pin connector for TCM
Ignition
-N93- 3) switched off and 8-pin connector page 01-302 .
29 + 34 infinite - Check wiring harness in transmission according to
1)
current wiring diagram; replace if necessary.
15 52 + 4 Solenoid valve 7 6-8 - Remove and install valve body
Ignition
-N94- 4) switched off
4 + 34 infinite
1)
1) Switch VAG1526 to highest resistance ( ) measuring range.

2) Solenoid Valve 5 -N92- is also called Pressure Valve 2 -N216-.
01-289

Test conditions
sockets
16 2 + 36 Shift lock 14 - 28
Ignition switched off - Check wiring per wiring diagram.
solenoid -N110-
3) - Check Multi-function Transmission
- Selector lever in P
Range (TR) switch page 01-306
- Perform test step 2 and 6
- Replace shift lock solenoid -N110-.

17 2) 18 + 34 Kick-down
Ignition switched off infinite 1)
- Check wiring per wiring diagram.
switch -F8-
not for E-gas Accelerator pedal not - Adjust or replace accelerator pedal
engines depressed cable.
Repair Manual, General, Engine,

Repair Group 20
less than 1.5
- Depress accelerator
pedal to kick-down.
2)This test cannot be performed on vehicles with E-gas. The kick-down switch -F8- in this case is integrated in the Throttle
Position (TP) Sensor (-G79-, -G185-).
01-290
Resistance measurement: switch multimeter to 20 K measuring range

Test conditions
step
sockets
18 14 + 42 Transmission VSS - Ignition - Check wiring per wiring diagram.
G38- 2) switched off
min. 0.8 K
max. 1.2 K
14 + 34 infinite - Replace transmission VSS -G38-, Fig.
1)
10, Page 01-28 .
14 + 54
42 + 54
42 + 34
15 + 34 Shielding for -G38- infinite
Ignition - Check wiring per wiring diagram.
1)
switched off
15 + 54
2) Transmission Vehicle Speed Sensor (VSS) -G38- is also referred to as Sensor for Transmission Output RPM -G195-.
01-291
Resistance measurement: switch multimeter to 20 K measuring range

Test step VAG Test of Test Specified Corrective action
conditions
1598/20 value
- Additional
sockets steps
19 16 + 44 Sensor for Ignition - Check wiring per wiring diagram.
transmission RPM - switched off
G182-
Only for hydraulic min. 0.23 K
control -E17- 2)
max. 0.30 K
44 + 34 infinite - Replace sensor for transmission
1)
RPM -G182- , Fig. 11, Page 01-
44 + 54 29 .
16 + 54
16 + 34
23 + 34 Shielding for -G182- Ignition infinite - Check wiring per wiring diagram.
1)
switched off
23 + 54
2) This test step can only be performed on transmission with hydraulic control E17. For information regarding the
transmission installed:
ratios, equipment
01-292
Resistance measurement: switch multimeter to 2 M measuring range

step conditions
1598/20 value
- Additional steps
sockets
20 21 + 22 Transmission Fluid (ATF) Ignition - Check wiring between 88-pin
Temperature sensor -G93- switched off connector on TCM and 8-pin
connector page 01-302 .
ATF - Check wiring harness in

temperature transmission; replace if necessary.
ATF temperature sensor -G93- is

integrated in wiring harness in
transmission.
approx. 20 C approx. 0.83
K 2)
K 2)
K 2)
21 + 34 infinite 1)
Ignition - Remove and install valve body
switched off
22 + 28
3) Repair Manual, 5 Spd. Automatic
21 + 54 infinite 1)
22 + 54
2) Permissible tolerance: 0.1 K
01-293

Test conditions
step
sockets
21 A) 41 + 28 Wiring to ECM (throttle infinite 1)
3)
Ignition switched - Check wiring per wiring
signal) off diagram.
41 + 34 ECM
disconnected
41 + 55
41 + 26
41 + xx 2) less than 1.5
2) Corresponding terminal assignment at Engine Control Module (ECM)
Electrical wiring diagrams Troubleshooting & Component Locations
A) Signal is transmitted to Transmission Control Module (TCM) via the Engine Control Module (ECM). Test is only for vehicles
without CAN-Bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00; Code letters, enginer/transmission allocation, ratios,
equipment
01-294

Test conditions
step
sockets
22 A) 35 + 28 Wiring to ECM (fuel more than
1)
consumption/load signal) 40 K
switched off
- Disconnect connections to other
35 + 34 - ECM components which also receive this
disconnected signal and repeat measurement.
35 + 55
35 + 26
35 + xx less than 1.5 - Check these components for short
2)
circuit if necessary (e.g. on-board
computer).
Change Measure Repair Manual, Electrical Equipment,

measuring range Voltage Repair Group 01
to 20 V
35 + 34 Approx. 5 V
Ignition
switched on
35 + 28
1) - ECM
disconnected
2) Corresponding terminals at Engine Control Module (ECM).
Electrical Wiring Diagrams & Component Locations
without CAN-Bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00; Code letters, engine and transmission allocation,
ratios, equipment
01-295

Test conditions
step
sockets
23 A) 40 + 28 Wiring to ECM (engine 15 - 80 K
3)
RPM signal) switched off
- Check on-board computer.
40 + 34 - ECM
disconnected
40 + xx less than 1.5 Repair Manual, Electrical
2) Equipment, Repair Group 01
24 A) 20 + 28 Wiring to ECM (torque infinite 1)

3)
reduction) switched off
20 + 34 - ECM
disconnected
20 + 55
20 + 26
20 + xx less than 1.5
2)
2) Corresponding terminal assignment at Engine Control Module (ECM).
Electrical Wiring Diagrams & Component Locations binder
without CAN-Bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00; Code letters, aggregate allocation, ratios,
equipment
01-296

Test conditions
step
sockets
25 A) 51 + 28 Wiring to ECM (upshift/downshift infinite 1)
3)
signal) off diagram.
51 + 34 - ECM
disconnected
51 + 55
51 + 26
51 + xx less than 1.5
2)
2) Corresponding terminal assignment at Engine Control Module (ECM).
Electrical Wiring Diagrams & Component Locations
without CAN-Bus
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 00; Code letters, aggregate allocation, ratios,
equipment
01-297

Test conditions
step
1598/20sockets - Additional steps value
26 13 + 34 Tiptronic approx. 10
Ignition switched - Check wiring according to wiring
switch - V
on diagram.
13 + 6 F189-
- Selector lever in D
but not in tiptronic gate
approx. 20
Ignition switched
mV - Check magnet on lateral gate cover 1)
on
- Repair shift mechanism, if necessary
- Selector lever replace gate cover or circuit board with
tiptronic gate Tiptronic switch -F189 1)

1)The Tiptronic Switch -F189- receives its tiptronic gate recognition information or tiptronic up- and down-shift information via
the large magnet which is mounted on the lateral gate cover of the gate cover. If the switch has become detached, the gate
cover must be replaced.
01-298

Test conditions
1598/20sockets - Additional steps value
27 46 + 54 Tiptronic less than With the Tiptronic Switch the driver

Switch - Ignition switched off can manually select the desired
1.5V
46 + 55 F189- - Selector lever in driving range 2)
Tiptronic gate
approx. - Check wiring according to wiring
battery diagram. If installed also check
- Selector lever in voltage wiring to Tiptronic steering wheel
Tiptronic gate and up-
shift switch actuated
46 + 34 approx. 12V - Check magnet on lateral gate
46 + 6 cover 1)
- Repair shift mechanism, if
- Selector lever in necessary replace gate cover or
Tiptronic gate circuit board with Tiptronic switch -
- Selector lever in F189- 1)
Tiptronic gate and
downshift switch Repair Manual, T5 Spd.
activated Automatic Transmission 01V,
Repair Group 37
Continued approx.
Ignition switched on - Perform test step 28
15mV
- Selector lever in
Tiptronic gate and up-

shift switch activated
01-299

Test step VAG1598/20sockets Test of Specified Corrective action
Test conditions
- Additional steps value
27 47 + 34 Tiptronic approx. 12V With the Tiptronic Switch the

Switch - driver can manually select the
cont'd 47 + 6 F189- - Selector lever in D desired driving range 2)
- Selector lever in
Tiptronic gate - Check wiring according to
wiring diagram. If installed also
- Selector lever in check wiring to Tiptronic
Tiptronic gate and up - steering wheel
shift switch activated
approx.15 - Check magnet on lateral gate

Ignition switched on mV
cover 1)
- Selector lever in
Tiptronic gate and
down-shift switch
activated
46 + 54 less than
Ignition switched off - Repair shift mechanism, if
1.5V necessary replace gate cover
47 + 55 - Selector lever in or circuit board with Tiptronic
Tiptronic gate switch -F189- 1)
Continued approx. Repair Manual, 5 Spd.
Ignition switched off Automatic Transmission 01V,
battery
voltage Repair Group 37
- Selector lever in
Tiptronic gate and
down-shift switch - Perform test step 28

activated
Notes and footnotes for test step 27 are on the next page.
01-300
1)The Tiptronic Switch -F189- receives its tiptronic gate recognition information or tiptronic up- and down-shift information via
the large magnet which is mounted on the lateral gate cover of the gate cover. If the switch has become detached, the gate
cover must be replaced.
2) If the selector lever in the Tiptronic gate is pressed toward the rear (-) or on vehicles with Tiptronic sport steering wheel one
of the minus (-) buttons on steering wheel is pressed, a manual shift-down can be performed (down-shift). If the selector lever
in the Tiptronic gate is pressed toward the front (+) or on vehicles with Tiptronic sport steering wheel one of the plus (+)
buttons on steering wheel is pressed, a manual up-shift-can be performed (up-shift).
01-301
Resistance measurement
Test conditions
step
sockets
28 A) 85 + 28 Wiring connection of TCM to infinite 1)
3)
ECM (CAN-bus) off diagram.
85 + 34 ECM
disconnected
86 + 28
3)
86 + 34
85 + xx less than 1.5 Further information on CAN-bus
2) page 01-263
86 + xx
2)
2) Applicable terminal assignment at Engine Control Module (ECM).
Repair Manual, Fuel Injection & Ignition, Repair Group 24
A) Testing only for vehicles with a CAN-bus
ratios, equipment
01-302
Wiring between transmission and 88-pin

connector for Transmission Control
Module (TCM) -J217-, testing
Perform if:
Output Diagnostic Test Mode (DTM) or
Electrical test indicates malfunctions in the

transmission, the TCM -J217-, or in the
corresponding wiring.
Test conditions
Connect VAG1598/20 adapter only to 88-pin

connector of transmission wiring harness.
Perform measurements with VAG1598/20

adapter on the outside of the vehicle
- Remove noise insulation panel.

- Remove bracket -1- for noise insulation panel.
01-303
Wiring to 16-pin connector on transmission,

testing
- Turn 16-pin connector -4- on transmission to release bayonet catch.
- Use multimeter (Fluke 83 or equivalent) to test for continuity between

terminals of 16-pin connector and sockets on VAG1598/20 adapter.
Resistance specifications table, page 01-304 .
01-304
Resistance specifications
Terminal on Socket on VAG1598/20 Specification Corrective action
16-pin connector adapter

1 42 1.5 - Repair open circuit according to current wiring diagram.
Check connectors for:
- contact corrosion
- ingress of water
- leaks
2 5 1.5
3 1 1.5
4 32 1.5
5 16 1.5
6 44 1.5
7 29 1.5
8 30 1.5
9 33 1.5
10 14 1.5
11 4 1.5
12 52 1.5
13 22 1.5
01-305
Terminal on Socket on VAG1598/20 Specification Corrective action
16-pin connector adapter

14 21 1.5 - Repair open circuit according to current wiring diagram.
- Check connectors
15 Vacant
16 53 1.5
Notes:
If the readings in these tests match the specifications, check the wiring harness in the transmission.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 38; removing and installing valve body
Only replace relevant solenoid valves if there are no faults found in the wiring harness in the transmission.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 38, valve body removing and installing
01-306
Multi-function Transmission Range (TR)

switch, checking
Note:
Check the measuring value block for the TR-

switch display group number 004 page 01-
203 before checking the TR-switch.
Be sure that selector lever cable is properly

adjusted.
Two different multi-function switches were

used in production:
1. Multi-function switch with 8 - pin connector

checking starting page 01-308 .
2. Multi-function switch with 10 - pin connector

checking starting page 01-319 .
01-307
Multi-function Transmission Range (TR)

switch -F125- (8-pin connector), testing
1. Function test
- Release spring catch securing 8-pin connector -2- to connector on

wiring to multi-function TR switch.
- Unclip connector to multi-function TR switch from retainer or remove
retainer together with connector from transmission to gain better
access to the pins in the connector.
- Pin assignment for 8 - pin connector of Multi-function (TR) switch -

F125-
- Use multi-meter VAG 1526A or Vehicle Diagnosis, Measuring and
Information System VAS 5051.
01-308
Transmission with Multi-function Transmission Range (TR) switch -F125- with 8 - pin connector, checking

Test Connector Test of Specified Corrective action
Test conditions
step pins at F 125
1 1+7 Multi-function infinitive

Ignition switched - Check connector on multi-function
TR switch - 1)
off TR switch for corrosion, water ingress
1+6 F126- or loose connection
- Selector lever in P,
R, N, D, 4, 3, and 2
1+2 smaller than - If necessary adjust selector lever
Ignition switched
off 2 cable
N, and D Repair Manual, 5 Spd. Automatic
- Selector lever in R, infinitive

1)
4, 3, and 2
1+3 smaller than

Ignition switched
off 2
- Selector lever in R,
N, and 4
Continue infinitive
Ignition switched - Replace multi-function TR switch
1)
off

D, 3, and 2
01-309

Test step Connector pins Test Specified Corrective action
Test conditions
at F 125 of
Continued 1+4 infinitive 1)

Ignition switched - Check connector on multi-function TR
off switch for corrosion, water ingress or loose
connection
- Selector lever in N,
1 D, 4, and 2
1+5 infinitive 1)
- Selector lever in P, - If necessary adjust selector lever cable
R, and 3
smaller than Repair Manual, 5 Spd. Automatic

Ignition switched
2 Transmission 01V, Repair Group 37
off
- Selector lever in D,
4, and 3
1+8 infinitive 1)
R, N, and 2
smaller than
Ignition switched
off 2
- Selector lever in R
Continue infinitive
- Selector lever in P, - Replace multi-function TR switch
1) Repair Manual, 5 Spd. Automatic

N, D, 4, 3, and 2
01-310

Test step Connector Test of Specified Corrective action
Test conditions
pins at F 125
Continued 6+7 Part No. signal of infinitive

Ignition switched - Replace multi-function TR switch
Multi-function TR 1)
off
to switch
- Selector lever in R, Repair Manual, 5 Spd.
D, 4, 3, and 2 Automatic Transmission 01V,
1
Repair Group 38
less than 2 The Part No. signal for the Engine
Ignition switched
Control Module (ECM) is being
off
checked
and N
Note:
If function check was OK, check voltage supply to Multi-function TR switch -F125- page 01-311
01-311
2. Multi-function Transmission Range (TR)

switch -F125- (8-pin connector), testing
- Release spring catch securing 8-pin connector -2- to connector on

wiring to Multi-function TR switch.
- Check at connector with spring clips (cavities) to Transmission Control
Module (TCM)
- Pin assignment for 8 - pin connector of multi-function (TR) switch -

F125- (to TCM)
Information System VAS 5051
Cavity in connector Test condition Specified value

1+6 Ignition switched on Approx. battery voltage
01-312
- If the specified value is not read, check fuses

and wiring connectors according to wiring
diagram and make necessary repairs.
Note:
If the check results and the voltage supply to the

Multi-function TR switch were OK, check wiring
connections from Transmission Control Module
(TCM) -J217- to Multi-function Transmission
Range (TR) switch page 01-316
01-313
3. Wiring from Transmission Control Module

(TCM) -J217- to Multi-function Transmission
Range (TR) switch -F125- (8-pin connector),
checking

- Disconnect connector from TCM -J217-, located in front of right seat
under the cover in the footwell page 01-20 .
- Connect test box VAG 1598/20 to harness connector.
- Connect both 8-pin connectors -2- to multi-function switch -F125- as

shown in the illustration.
Information System VAS 5051
01-314

Test conditions
step
sockets
1 36 + 34 Multi-function Transmission Approx. 12
Ignition switched - Check connector at multi-function
Range (TR) switch -F125- V
on switch for corrosion
36 + 6
- Selector lever in P, - Check wiring per wiring diagram
N, and D
Less than 1 - Check fuses
V
4, 3, and 2
- Check voltage supply to -F125-
page 01-311 .
8 + 34 Approx. 12
Ignition switched - Check wiring from 88-pin control
V
on module to 8-pin connector page
8+6 01-319 .
N, and 4
Less than 1
V
D, 3, and 2
37 + 34 - Selector lever in N, Approx. 12

V
D, 4, and 2
37 + 6
Less than 1
V
R, and 3
9 + 34 Approx. 12
- Selector lever in D,
V
4, and 3
9+6
Less than 1
V
R, N, and 2
01-315

Test conditions
step
sockets
2 36 + 8 Multi-function Transmission less than 26 - Check connector at multi-function
Ignition switched
Range (TR) switch -F125
off switch for corrosion
- Selector lever in N
infinitive - Check wiring from 88-pin control
- Selector lever in P, 1)
R, D, 4, 3, and 2 module to 8-pin connector page
01-319 .
37 + 9 less than 26 - Perform test steps 6 and 27.
Ignition switched
off
and 4
infinitive
- Fuse 31 removed 2) 1)
R, N, 3 and 2
37 + 36 less than 26
Ignition switched
off
- Selector lever in N,
and D
Electronic Stabilization Program (ESP), electrical testing Page 1 of 65
01-301
Electronic Stabilization
Program (ESP), electrical
testing
If the On Board Diagnostic (OBD) sequence
does not provide any indication of the source of
the malfunction, work through all of the
electrical test steps.
If the OBD sequence identifies the source of the

malfunction, only carry out the test steps
recommended in the DTC table (specific
testing).
01-302
Test requirements
The "Automatic Test Sequence" was carried

out and it was determined that the
Transmission Control Module (TCM) and
Engine Control Module (ECM) only contain
DTCs relating to ABS.

select the address word 00 with ignition
switched on;
- After completing electrical test, check and

erase DTC memories of Transmission Control
Module (TCM) and Engine Control Module
(ECM).
Multi-pin harness connector for ABS control module -J104- in proper

condition, with no bent, broken or corroded terminals. Replace any
damaged terminals using VAS1978 wiring repair kit.
01-303
Note:
The operation manual for the VAS1978 wiring

harness repair kit generally forbids the repair of
any lines in the ABS or related systems. This rule
only pertains to the shielded lines in these
systems.
Ignition and electrical consumers switched

off before beginning testing (headlights,
lighting, fan, etc.).
For steps 13 through 16, raise the vehicle

until the wheels rotate freely. On vehicles
with manual transmission put the gear shift
lever in neutral. On vehicles with automatic
transmission move the selector lever to
position "N".
01-304
Required special tools and test equipment:
VAG1551 Scan Tool (ST) or VAG1552 mobile

scan tool
VAG1598/20 test box
VAG1594 connector test kit
VAG1526 Multimeter
VAG1310A Pressure gauge
01-305
Connecting VAG1598/20 test box and

checking ESP system
- Remove ABS control module -J104-.
Repair manual, Brake System, Repair Group

45
- Disconnect multi-pin connector from ABS control

module -J104-.
- Check multi-pin connector between harness

connector and ABS control module -J104-.
The socket designations on the VAG1598/20 test box are identical to the
terminal designations on the ABS control module -J104- and on the wiring
harness connector.
- Connect VAG1598/20 test box to multi-pin connector of wiring harness.
01-306
Terminal allocation, ABS control module -J104-
Multi-pin connector at ABS control module

(w/EDL) -J104-
Terminal Connected to... Terminal
1 Voltage supply, terminal 15 -
Traction control switch 5

2 ABS return flow pump relay -J105- (B+) 86
ABS solenoid valve relay -J106- (B+) 86
Voltage supply for steering angle sensor -G85- via 5

terminal 15
3 Hydraulic unit; activation of left front ABS outlet 15
valve -N102-
4 Hydraulic unit; activation of right rear ABS outlet 12
valve -N135-
5 Hydraulic unit; activation of left front ABS inlet 8
valve -N101-
6 Hydraulic unit; activation of right rear ABS inlet 2
valve -N133-
7 ABS return flow pump relay -J105- (GND) 85
8 Left front ABS wheel speed sensor -G47- -
For vehicles with all-wheel-drive:
01-307
Multi-pin connector at ABS control module (w/EDL) -

J104-
For vehicles with front-wheel-drive:

(GND)
11 Right rear ABS wheel speed sensor -G44- -
12 Right rear ABS wheel speed sensor -G44- -
(GND)
14 Left rear ABS wheel speed sensor -G46- (GND) -
15 Right front ABS wheel speed sensor -G45- -
16 Right front ABS wheel speed sensor -G45- -
(GND)
17 Not assigned -
01-308
Multi-pin connector at ABS control

module (w/EDL) -J104-
18 Sensor for transverse acceleration -G200-; signal wire (control 2
module 4B0 907 389)
18 Sensor for transverse acceleration -G200-; signal wire (combined 4
sensor for rotation rate and transverse acceleration) (control
module 8D0 907 389/A/D/E)
19 Sensor for transverse acceleration -G200-; (Ground -GND-) (control 1
module 4B0 907 389)
19 not occupied; (control module 8D0 907 389/A/D/E) -
19 not occupied; (control module 8D0 907 389A) -
20 ABS return flow pump relay -J105- 87
Hydraulic unit; control wire for ABS return flow pump -V39- 14
21 Not assigned -
22 Hydraulic pump for traction control -V156-; voltage supply 2
23 Not assigned -
24 Hydraulic pump for traction control -V156-; (GND) 1
01-309

(w/EDL) -J104-
25 Hydraulic unit; activation of left rear ABS outlet valve - 11
N136-
26 Hydraulic unit; activation of right front ABS inlet valve -N99- 5
27 Not assigned -
28 Ground (GND) supply, terminal 31 -
29 Ground (GND) supply, terminal 31 -
30 Not assigned -
31 Instrument cluster; activation of traction control indicator 15
light; (control module 4B0 907 389)
31 Rear left wheel speed sensor output; (control module 8D0 -
907 389/A/D/E)
32 Instrument cluster; ABS/EDL warning light activation 26
33 Not assigned -
01-310

34 Sender for rotation rate -G202-; voltage supply; (control module 2
4B0 907 389)
34 Sender for rotation rate -G202-; voltage supply (combined sensor 1
for rotation rate and transverse acceleration) (control module 8D0
907 389/A/D/E)
35 Not assigned -
36 not occupied; (control module 4B0 907 389) -
36 ABS solenoid valve relay -J106- (GND); (control module 8D0 907 85
389/A/D/E)
37 ABS solenoid valve relay -J106- (GND); (control module 4B0 907 85
389/A/D/E)
38 Not assigned -
39 Not assigned -
01-311

(w/EDL) -J104-
40 Not assigned -
41 Not assigned -
42 Brake light switch -F; brake test switch 4
43 Not assigned -
44 Traction control switch 6
45 Not assigned -
46 Diagnostic connector; K-wire 7
47 Not assigned -
48 Brake light switch -F-; brake light switch 2
49 ABS hydraulic unit -N55-; activation of pilot valve -1- 7
traction control -N225-
50 ABS hydraulic unit -N55-; activation of pilot valve -2- 6
traction control -N226-
51 Voltage supply; terminal 30 for hydraulic pump for -
traction control -V156-;
01-312

(w/EDL) -J104-
52 ABS hydraulic unit -N55-; activation of high pressure 4
switch valve -2- traction control -N228-
53 ABS hydraulic unit -N55-; activation of left rear ABS inlet 3
valve -N134-
54 ABS hydraulic unit -N55-; activation of high pressure 1
switch valve -1- traction control -N227-
55 ABS hydraulic unit -N55-; activation of right front ABS 9
outlet valve -N100-
56 not used -
57 not used -
58 not used -
59 not used -
60 not used -
61 Not assigned -
62 Not assigned -
63 Not assigned -
01-313

(w/EDL) -J104-
64 CAN-bus; (Engine Control Module (ECM); Transmission EWD
Control Module (TCM),
2
steering angle sensor -G85-)
65 CAN-bus shielding; (control module 8D0 907 389/A/D/E) -
66 CAN-bus; (Engine Control Module (ECM); Transmission EWD
Control Module (TCM),
3
steering angle sensor -G85-)
67 Sender 1 for brake booster -G201-; (GND) (control module 1
4B0 907 389)
67 Sender 1 for brake booster -G201-; voltage supply (control 1
module 8D0 907 389/A/D/E)
68 Sensor for brake pressure -G201-; signal wire 2
69 Sender 1 for brake booster -G201-; voltage supply (control 3
module 4B0 907 389)
69 Sender 1 for brake booster -G201-; (GND) (control module 3
8D0 907 389/A/D/E)
01-314

70 Left-rear wheel speed sensor output; (control module 4B0 EWD
907 389)
70 Instrument cluster; activation of traction control indicator 15
light (control module 8D0 907 389/A/D/E)
71 Speed sensor output rear right EWD
72 Front left wheel speed sensor output; (control module 8D0 EWD
907 389/A/D/E)
73 Front right wheel speed sensor output; (control module 8D0 EWD
907 389/A/D/E)
74 Not assigned -
75 Sensor for transverse acceleration -G200-; voltage supply; 3
(control module 4B0 907 389)
76 Parking brake warning light switch -F9- EWD
01-315

77 Sender for rotation rate -G202-; test signal; (control module 4B0 5
907 389)
77 Sender for rotation rate -G202-; test signal (combined sensor for 3
rotation rate and transverse acceleration); (control module 8D0 907
389/A/D/E)
78 Sender for rotation rate -G202-; reference signal; (control module 4
4B0 907 389)
78 Sender for rotation rate -G202-; reference signal (combined sensor 5
for rotation rate and transverse acceleration); (control module 8D0
907 389/A/D/E)
79 Sender for rotation rate -G202-; signal wire; (control module 4B0 3
907 389)
79 Sender for rotation rate -G202-; signal wire (combined sensor for 6
389/A/D/E)
80 Sender for rotation rate -G202-; (GND); (control module 4B0 907 1
389)
80 Sender for rotation rate -G202-; (GND) (combined sensor for 2
389/A/D/E)
01-316

(w/EDL) -J104-
81 Not assigned -
82 Not assigned -
83 Not assigned -
84 Not assigned -
85 Not assigned -
86 Instrument cluster; standing time signal; (control module 11
8D0 907 389/A/D/E)
87 Not assigned -
88 Not assigned -
01-317
Notes:
For test table
The socket designations of the VAG1598 test box are identical to the terminal designations of the ABS control module
(w/EDL) -J104- in the wiring diagram. Incorrect test procedures can cause damage to the system. Do not bridge any
terminals other than those listed in the table.
Specified values refer to readings on the VAG1526 and are not necessarily applicable for other test units.
If the measured values do not match specifications, carry out the corrective actions listed on the right side of the table.
If values are obtained, also check wiring for intermittent loose terminals and short circuit to B+ and Ground (GND). This
applies especially to sporadic malfunctions.
Use the VAG1594 connector test kit for checking continuity (bridges).
If the measured values only differ slightly from the specifications, clean the sockets and harness connectors of the testers
and adapter leads (using contact spray G 000 700 04) and repeat the test. Before replacing actual components, check
wiring and connections once more. This is especially important if the specification for a resistance test is under 10 .
01-318
Electrical test; steps 1-12
Resistance measurement: Select measurement range on VAG1526 (200 )

1598/20
steps
1 5+3 Left front ABS inlet valve - An infinitely high resistance indicates
-N101-, left front ABS an open circuit. Check for this.
outlet valve -N102-
2 55 + 26 Right front ABS inlet - A resistance less than the specified
valve -N99-, right front value indicates a short circuit between
ABS outlet valve -N100- both lines. Check for this.
9 22
3 53 + 25 Inlet valve -N134-, outlet - Check electrical wiring for short
valve -N136- left-rear circuit to Ground (GND) or B+.
01-319

1598/20
steps
4 6+4 Inlet valve -N133-, Electrical Wiring Diagrams,

outlet valve -N135- Troubleshooting & Component Locations
right-rear
- If the electrical wiring is OK, replace the
9 22 hydraulic unit.
5 49 + 50 - An infinitely high resistance indicates an
Pilot valve -1-
traction control - open circuit. Check for this.
N225-
Pilot valve -2- 12 - A resistance less than the specified

traction control - 28 value indicates a short circuit between
N226- both lines. Check for this.
01-320

1598/20
steps
6 52 + 54 - Check electrical wiring for short
High pressure switch
valve -1- traction control circuit to Ground (GND) or B+.
-N227-
W
16
High pressure switch
valve -2- traction control
Locations
-N228-
- If the electrical wiring is OK,
replace the hydraulic unit.
7 8 + 10 1) Left front ABS wheel speed - An infinitely high resistance
sensor -G47-
indicates an open circuit. Check for
9 + 10 2) 400 this.
2300
Outlets on ABS control module -J104- differ depending on installed equipment
1) Vehicles with all-wheel-drive
2) Vehicles with front-wheel-drive
01-321
Resistance measurement: Select measurement range on VAG1526 (2k or 20 k )

1598/20
steps
8 15 + 16 Right front ABS - A resistance less than the specified value
wheel speed indicates a short circuit between both lines.
sensor -G45- Check for this.
9 13 + 14 Left rear ABS - Check electrical wiring for short circuit to
wheel speed Ground (GND) or B+.
sensor -G46- 400
2300
10 11 + 12 Right rear ABS Electrical Wiring Diagrams,
wheel speed Troubleshooting & Component Locations
sensor -G44-
- If the electrical wiring is OK, replace the
relevant ABS wheel speed sensor.
01-322

1598/20
steps
11 2 + 37 1) Activation of ABS - An infinitely high resistance indicates
solenoid valve relay - an open circuit.
J106-
2 + 36 2)
- A resistance less than the specified
value indicates a short circuit between
both lines.
12 2+7 Activation of ABS 0W - Check electrical wiring for short circuit
return flow pump relay 70 to Ground (GND) or B+.
-J105-
- If the electrical wiring is OK, replace

the relay.
1) Vehicles with control module 4B0 907 389
2) Vehicles with control module 8D0 907 389/A/D/E
01-323
Electrical test; steps 13-27
Function test
Test requirements
step value
sockets
13 1) Bridge Inlet valve -N101

Ignition on
and front left
1 + 2, brake line
connection
28+37 2)
28+36 3)
- for vehicles with Left front - If the wheel does not rotate, check the
automatic transmission, wheel can other wheels for free rotation. If yes, then
engage neutral position be rotated hydraulic brake lines are mixed-up
"N" by hand (switched). Check brake line connections
and coupling pieces. Make sure every
- Bridge terminals 5 + component is OK.
28
- Depress brake pedal
and hold.
See continuation on next page
1) This test step requires two technicians.
01-324
Continuation:
Function test
Test VAG Test of Test Specified value Corrective action
step requirements
1598/20
steps
13 1) Bridge Inlet valve -N101 and - If all wheels are blocked, inlet
front left brake line
valve is malfunctioning DTC
1 + 2, connection table, DTC 00257.
28+37 2)
28+36 3)
- Remove bridge The left-front

wheel remains
locked.
- Release brake
pedal.
01-325
Function test
Test requirements
step value
sockets
14 1) Bridge Inlet valve -N99-

Ignition on
and front right
1 + 2, brake line
connection
28+37 2)
28+36 3)
- for vehicles with Right front - If the wheel does not rotate, check the
28
and hold.
01-326
Continuation:
Function test
step requirements
1598/20
steps
14 1) Bridge Inlet valve -N99- and - If all wheels are blocked, inlet
front right brake line
28+37 2)
28+36 3)
- Remove bridge The right-front

wheel remains
locked.
- Release brake
pedal.
01-327
Function test
Test requirements
step value
sockets
15 1) Bridge Inlet valve -

Ignition on
N134- and rear
1 + 2, left brake line
connection
28+37 2)
28+36 3)
- for vehicles with Left rear - If the wheel does not rotate, check the
28
and hold.
01-328
Continuation:
Function test
step requirements
1598/20
steps
rear left brake line
28+37 2)
28+36 3)
- Remove bridge The left-rear

wheel remains
locked.
- Release brake
pedal.
01-329
Function test
Test requirements
step value
sockets
16 1) Bridge Inlet valve -

Ignition on
N133- and rear
1 + 2, right brake line
connection
28+37 2)
28+36 3)
- for vehicles with Right rear - If the wheel does not rotate, check the
28
and hold.
01-330
Continuation:
Function test
step requirements
1598/20
steps
rear right brake line
28+37 2)
28+36 3)
- Remove bridge The right-rear

wheel remains
locked.
- Release brake
pedal.
01-331
Function test: ABS warning light -K47-

Test requirements
step value action
sockets
17 - Function of ABS DTC memory checked and no DTC present
warning light -K47- in DTC memory of ABS control module -
J104-.
engaged.
01-332
Continuation:

step requirements
1598/20
steps
17 - Function of ABS warning light -

- Switch on - If ABS warning light does not come on,
ABS warning K47- lights up for two
ignition check voltage of electrical system and test
light -K47- (2) seconds and then wiring from terminal 32 of ABS control
goes out. module -J104- to instrument cluster for short
circuit to Ground (GND).
01-333
Continuation:

1598/20
steps
17 - Function of - The ABS warning lamp does not switch off after 2
ABS warning seconds. The red "brake system malfunction" symbol
light -K47-
lights up after 2 seconds. Check wire from terminal 32
of ABS control module -J104- to instrument cluster for
short circuit to B+ or open circuit.

Component Locations
- If voltage of electrical system is OK and wiring from

terminal 32 of ABS control module -J104- to instrument
cluster is intact there is a malfunction in instrument
cluster.
Repair Manual, Electrical Equipment, Repair Group

90; Instrument cluster
01-334

Test requirements
step value action
sockets
18 - Function of red "brake
Brake fluid level is OK
system malfunction"
symbol
Group 47
Function of ABS warning light -K47-

control module -J104- and retainer
catch engaged.
Switch on ignition
01-335
Continuation:

Test requirements
step
sockets
18 - Function of red The ABS/EDL indicator lamp - Malfunction in
- Connect VAG1551 scan tool
"brake system and the red "brake system
and select address word 03 instrument cluster
malfunction" malfunction" symbol light up.
symbol - For vehicles with automatic If the traction control indicator
transmission and instrument light is OK, it lights up as Repair Manual,
cluster with DIS, depress the well. Electrical
brake pedal and select a Equipment, Repair
driving gear. Group 90;
Instrument cluster
01-336
Function test: Traction control indicator light -K86-

Test requirements
step value action
sockets
19 - Function of traction DTC memory checked and no DTC
control indicator light - present in DTC memory of ABS control
K86- module -J104-.
engaged.
01-337
Continuation:

requirements
1598/20
steps
19 - Function of Traction control
- Switch on - If traction control indicator light does
traction indicator light -K86-
ignition not light up, check vehicle voltage and
control comes on for two wire from terminal 31 of ABS control
indicator light (2) seconds and module -J104- to instrument cluster for
Continuation: -K86- then goes out. short circuit to B+ and open circuit.
- If traction control indicator lights
continuously, test wiring from terminal
31 of ABS control module -J104- to
instrument cluster for short circuit to
Ground (GND).

Locations
01-338
Continuation:

1598/20
steps
19 - Function of - Are voltage of electrical system OK and wiring
traction control from terminal 31 of ABS control module -J104-
indicator light - to instrument cluster intact? malfunction in
K86- instrument cluster
Repair Manual, Electrical Equipment, Repair

Group 90; Instrument cluster
01-339

Test requirements
step value action
sockets
20 - Function of
ASR/ESP button
Function of traction control indicator light -
K86- already checked in step 19.
Multi-pin connector connected to ABS control
module -J104- and retainer catch engaged.
01-340
Continuation:

step requirements
1598/20
steps
20 - Function of - Switch on ignition
ASR/ESP
button
- Press ASR/ESP Traction control - Switch off ignition.

indicator light -K86-
button
lights up - Detach multi-pin connector from
ABS control module -J104- and
remove.
Traction control
- Press ASR/ESP - Connect VAG1598/20 test box.
indicator light -K86-
button again
goes out
01-341
Continuation:

Test requirements
step value
1598/20 - Additional work
sockets steps
20 28 + 44 Function of Ignition switched
ASR/ESP button on.
0.0 to 1.0 V
- ASR/ESP button not - Check wire from terminal 28 to Ground
pressed (GND).
- Check wiring from terminal 44 to
traction control button, terminal 6.
- Check voltage supply from terminal 5
of ASR/ESP button to terminal 15.

01-342
Continuation:

1598/20
steps
20 28 + 44 Function of 10.0 to 14.5

- ASR/ESP button - Check wire from terminal 28 to Ground
ASR/ESP V
pressed (GND).
button
- Check wiring from terminal 44 to traction
control button, terminal 6.
- Check voltage supply from terminal 5 of
ASR/ESP button to terminal 15.

- If no malfunctions can be found using the

procedures in these steps, replace the
ASR/ESP button.
01-343
Voltage measurement; set measurement range on VAG1526: 20 V =

1598/20
steps
21 1 + 28 Voltage supply to ABS Ignition 10.5 to 14.5 - Check wiring from terminals 28
control module -J104- via switched on. V and 29 to Ground (GND).
1 + 29 terminal 15
- Check wiring from terminal 1 to
terminal 15 via fuse (10A).

Locations
01-344

Test requirements
step value
sockets
22 - Voltage supply of
- Remove ABS solenoid valve relay -
solenoid valves via
J106-.
ABS solenoid valve
relay -J106-.
Repair Manual, Brake System,
Repair Group 45
10.5 to
- Check voltage supply for ABS - Check the relevant fuse,
14.5 V
solenoid valve relay -J106- at terminal 25A, and repair the wiring
30 for open circuit or short circuit to problem.
B+ or Ground (GND).
Electrical Wiring
Diagrams, Troubleshooting
& Component Locations
01-345
Continuation:

Test requirements
step value
sockets
22 - Voltage supply of
- Check wiring from ABS solenoid valve - Fix the wiring problem.
solenoid valves relay -J106- (terminal 87) to ABS
via ABS solenoid - If the power supply lines
hydraulic unit -N55- (terminal 10) for
valve relay -J106- are OK, replace the relay.
open circuit or short circuit to B+ or
. Ground (GND). - If the original malfunction
"ABS solenoid valve relay -
J106-" is still not fixed,
replace the ABS hydraulic
unit.
01-346

Test requirements
step value
sockets
23 - Voltage supply for
- Remove ABS return flow pump relay
ABS return flow
-J105-.
pump relay -J105-
via terminal 30
Repair Group 45
10.5 to
- Check voltage supply for ABS return - Check the relevant fuse,
14.5 V
flow pump relay -J105- at terminal 30 60A, and repair wire
for open circuit or short circuit to damage.
Ground (GND).
Electrical Wiring
Diagrams, Troubleshooting
01-347

Test requirements
step value action
sockets
24 - Ground (GND) supply and voltage - Remove ABS return flow
supply for ABS return flow pump - pump relay -J105-.
V39-
Repair Manual, Brake
System, Repair Group 45
01-348
Continuation:

Test requirements
step value action
sockets
24 -
Ground (GND) - Check wiring from ABS return flow pump relay - - Fix the
supply and voltage J105- (terminal 87) to ABS control module -J104- wiring
supply for ABS (terminal 20) and to ABS hydraulic unit -N55- problem.
return flow pump - (terminal 14) for open circuit or short circuit to B+
V39- or Ground (GND).
01-349
Continuation:

Test requirements
step value
sockets
24 -
Ground (GND) supply - Check the Ground (GND) for - Fix the open circuit
and voltage supply for ABS return flow pump at ABS or short circuit to B+ in
ABS return flow pump - hydraulic unit (terminal 13). Ground (GND).
V39-
01-350
Continuation:

Test requirements
step
sockets
24 Bridge
Function of ABS return flow
ABS return pump relay -J105-
7 + 28, flow pump installed
relay -J105-.
1+2
- Use VAG1598/20 to Voltage should be

measure voltage between 10.5 to
between terminals 20 14.5 V between
and 29. terminals 20 and
29.
- Switch on ignition for ABS return flow - If you do not measure any
max. 10 seconds and pump -V39- runs voltage between terminals 20
switch off again. and 29, replace the relay.
- If you measure voltage
between terminals 20 and 29,
the ABS return flow pump is
malfunctioning. Replace ABS
hydraulic unit -N55-.
01-351

Test requirements
step value
sockets
25 51 + 28 ABS control module -J104- is 10.5 to
- Check the wiring from ABS - Check the relevant
supplied with power at terminal 51 14.5 V
control module -J104- fuse, 25A, and repair
from terminal 30. The ABS control (terminal 51) to terminal 30 for the wiring problem.
module -J104- uses this voltage open circuit and short circuit to
supply as a voltage supply for the Ground (GND). Electrical Wiring
hydraulic pump for traction control
-V156. Diagrams,
Troubleshooting &
Component Locations
01-352

Test requirements
step value
sockets steps
26 28 + 48 Function of brake Ignition switched - Check wire from terminal 28 to

light switch -F- off Ground (GND).
0.0 to 1.0 V
- Operate brake
pedal. Electrical Wiring Diagrams,
10.0 to 14.5
V
Locations

Repair Group 45
01-353
Continuation:

Test requirements
step value
sockets steps
26 28 + 42 Function of brake light 10.0 to 14.5
switch -F-(Brake test V
switch)
- Operate brake
pedal. Electrical Wiring Diagrams,
0.0 to 1.0 V
Locations

Repair Group 45
01-354

1598/20
steps
27 1 + 76 Function of parking Ignition switched - Check wiring from terminal 1 to terminal
brake warning light on. 15 via fuse (10A).
switch -F9-
0.0 to 1.0
Parking brake - Check wiring from terminal 76 to parking
V
not engaged brake warning light switch -F9- for open
circuit or short circuit to B+.
- Set parking brake
10.0 to 14.5
V
01-355
Continuation:

1598/20
steps
27 1 + 76 Function of parking 0.0 to 1.0
Parking brake - Check Ground (GND) to parking brake
brake warning light V
not engaged warning light switch -F9-.
switch -F9-
- Set parking brake
10.0 to
14.5 V
- If no malfunction could be determined
using the procedures in these steps, replace
the parking brake warning light switch -F9-.
Electronic Stabilization Program (ESP) DTC table Page 1 of 96
01-356
Electronic Stabilization Program (ESP) DTC table

Notes:
Fulfill test requirements page 01-22 .
Connect the VAG1551 Scan Tool (ST) and select "Brake Electronics" via address word 03 page 01-4
Check the control module version page 01-231 and press the button.
Press buttons -0- and -2- to select "Check DTC Memory" function 02. Press -Q- button to confirm input.
Each malfunction is assigned a 5-digit Diagnostic Trouble Code (DTC). The DTC is located in the left column of the DTC
table. If you have switched the printer on by pressing the "PRINT" button, the VAG1551 scan tool (ST) prints the message
identifying the malfunction and the DTC. Otherwise, DTCs are not displayed by the VAG1551 scan tool.
The contents of DTC memory remain stored until memory is erased, page 01-15 .
Sporadically occurring malfunctions are identified via indication of "/SP" on the right-hand side of the display.
Static malfunctions that cannot be detected when the vehicle is stationary are also identified with "/SP" if the ignition has
been switched off and then on again.
The following DTC table includes all the DTCs that can be stored by the ABS control module -J104- and displayed and
printed out by the VAS5051 tester or VAG1551 scan tool. Malfunctions are listed by DTC number.
01-357
DTC table; DTCs from 00000 to 00526
Printed output from VAG1551 Possible cause Corrective action

Scan Tool (ST)
DTC
00000
No malfunction recognized! If one or more indicator lamps light up anyway, - See section "Overview of
one of the wires that activates the indicator indicator lamp functions"
If this display appears, process is lamps may be malfunctioning. page 01-222 .
concluded. No DTCs are stored in
DTC memory. Missing signal from parking brake warning light Check the parking brake
switch -F9-. (parking brake set or released). warning light switch -F9-.
If there are still problems or
malfunctions anyway, check the - "Read measuring value block"
following points: function 08 page 01-256 ,
display group 2.
Missing signal from brake light switch -F. Check the brake light switch
-F.
- "Read measuring value block"
function 08 page 01-256 ,
display group 2.
01-358
Printed output from Possible cause Corrective action

VAG1551 Scan Tool
(ST)
DTC
00000
No malfunction The zero position learned by the steering angle Check the zero position of the
recognized! sensor -G85- during straight-ahead driving in the steering angle sensor -G85-.
zeroing procedure has become misadjusted.
- "Read measuring value block" function
08 page 01-256 , display group 2, 5
Continuation:
If no malfunction can be found, and there is still a - Expand troubleshooting to include the
problem, there may be a mechanical malfunction (e.g. "Electrical test" page 01-301 .
solenoid valve sticking).
00257
Left front ABS inlet valve Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", steps 1 + 13
-N101- in wiring between ABS hydraulic unit -N55- and page 01-318 , and page 01-323
ABS control module -J104-.
- If the electrical test does not reveal any
Left front ABS inlet valve -N101- malfunctioning malfunctions, check all wiring and
connectors for loose contacts.
ABS control module -J104- malfunctioning
- If no problems are found after
implementing the specified steps,
replace the control module.
01-359

VAG1551 Scan Tool
(ST)
DTC
00259
Right front ABS inlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", steps 2 +14
valve -N99- in wiring between ABS hydraulic unit and ABS page 01-318 and page 01-323
control module -J104-.
Right front ABS inlet valve -N99- malfunctioning. malfunctions, check all wiring and
implementing the specified steps, replace
the control module.
00265
Left front ABS outlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "Electrical test", step 1 page
valve -N102- in wiring between ABS hydraulic unit and ABS 01-318 .
Left front ABS outlet valve -N102- malfunctioning. malfunctions, check all wiring and
the control module.
01-360

VAG1551 Scan Tool
(ST)
DTC
00267
Right front ABS outlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "Electrical test", step 2 page
Right front ABS outlet valve -N100- malfunctions, check all wiring and
malfunctioning connectors for loose contacts.
ABS control module -J104- malfunctioning - If no problems are found after
the control module.
00273
Right rear ABS inlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", steps 4 +16
Right rear ABS inlet valve -N133- malfunctioning malfunctions, check all wiring and
the control module.
01-361

VAG1551 Scan Tool
(ST)
DTC
00274
Left rear ABS inlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", steps 3 +15
Left rear ABS inlet valve -N134- malfunctioning malfunctions, check all wiring and
the control module.
00275
Right rear ABS outlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "Electrical test", step 4 page
Right rear ABS outlet valve -N135- malfunctions, check all wiring and
malfunctioning. connectors for loose contacts.
ABS control module -J104- malfunctioning - If no problems are found after
the control module.
01-362

VAG1551 Scan Tool
(ST)
DTC
00276
Left rear ABS outlet Open circuit, short circuit to B+ or Ground (GND) - Carry out "Electrical test", step 3 page
Left rear ABS outlet valve -N136- malfunctioning malfunctions, check all wiring and
the control module.
01-363
Printed output Possible cause Corrective action

from VAG1551
Scan Tool (ST)
DTC
00283
Left front ABS wheel Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
Implausible signal ABS wheel speed sensor rotor dirty or Repair Manual, Brake System, Repair Group 45
damaged.
- Check rotor, clean or replace
ABS wheel speed sensor -G47- Repair Manual, Brake System, Repair Group 45
malfunctioning.
Repair Group 40
- "Read measuring value block" display group 1 page

01-256 .
00283
Left front ABS wheel
Incorrect control module - Check control module identification page 01-231 .
speed sensor -G47-
Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
Open circuit/short wiring between ABS wheel speed block", and no malfunction could be determined in the
circuit to B+ sensor -G47- and ABS control module - wiring or the ABS wheel speed sensor, replace the ABS
J104-. control module -J104-.
01-364

from VAG1551
Scan Tool (ST)
DTC
00285
Right front ABS Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
-G45-
Implausible signal damaged.
malfunctioning.
Repair Group 40
or:
- "Read measuring value block", display group 1
page 01-256 .
- Carry out "Electrical test", step 8 page 01-318
Right front ABS
Incorrect control module - Check control module version page 01-231 .
wheel speed sensor
circuit to B+ J104-. ABS control module -J104-.
01-365

from VAG1551
Scan Tool (ST)
DTC
00287
Right rear ABS Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
-G44-
Implausible signal damaged.
malfunctioning.
or: Repair Group 42

page 01-256 .
Right rear ABS Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
wheel speed sensor wiring between ABS wheel speed block", and no malfunction could be determined in the
-G44- sensor -G44- and ABS control module - wiring or the ABS wheel speed sensor, replace the
J104-. ABS control module -J104-.
Open circuit/short
circuit to B+
01-366

from VAG1551
Scan Tool (ST)
DTC
00290
Left rear ABS wheel Left rear ABS wheel speed sensor - - Check installation of ABS wheel speed sensor.
Implausible signal ABS wheel speed sensor rotor dirty or Repair Manual, Brake System, Repair Group 45
damaged.
malfunctioning.
or: Repair Manual, Suspension, Wheels, Steering,
Repair Group 42

page 01-256 .
Left rear ABS wheel Open circuit or short circuit to B+ in - If nothing is displayed during "Read measuring value
Open circuit/short J104-. ABS control module -J104-.
circuit to B+
01-367

VAG1551 Scan Tool
(ST)
DTC
00301
ABS return flow pump - Open circuit or resistance too high in Ground (GND) supply - "Read measuring value
V39 - from ABS return flow pump relay - J105 - (terminal 85) to block", display group 6
ABS control module -J104- (terminal 7). page 01-256
- Carry out "Electrical test",
step 12 page 01-318 .
Open circuit or resistance too high in voltage supply from

ABS return flow pump relay - J105 - (terminal 86) to ABS
control module -J104- (terminal 2).
See continuation on
next page
01-368

Scan Tool (ST)
DTC
00301
ABS return flow pump -V39 -
Short circuit to B+ or Ground (GND) in one of the
activation wires.
Continuation: Voltage supply for ABS return flow pump relay - - Carry out "Electrical test", step
J105-, terminal 30. 23 page 01-323 .
ABS return flow pump relay -J105- or ABS - Carry out "Electrical test", step
hydraulic unit -N55- malfunctioning. 24 page 01-323 .

page
01-369

VAG1551 Scan Tool
(ST)
DTC
00301
Continuation:
ABS return flow pump - Open circuit or short circuit to Ground (GND) from ABS - Carry out "Electrical test",
V39 - return flow pump relay -J105- (terminal 87) to the ABS step 24 page 01-323 .
control module -J104- (terminal 20) and the ABS hydraulic
Implausible signal unit -N55- (terminal 14). - Fix the wiring problem.
Open circuit or short circuit to B+ in the Ground (GND) Electrical Wiring Diagrams,
supply of the ABS return flow pump. Troubleshooting & Component
Locations
01-370

VAG1551 Scan Tool
(ST)
DTC
00302
ABS solenoid valve relay Open circuit or resistance too high between Ground (GND) - "Read measuring value
-J106- of ABS solenoid valve relay - J106 - (terminal 85) and ABS block", display group 6
control module -J104- (terminal 37). page 01-256
step 11 page 01-318 .
Open circuit or resistance too high between voltage supply of

ABS solenoid valve relay - J106 - (terminal 86) and ABS
control module -J104- (terminal 2).
Short circuit to B+ or Ground (GND) in one of the activation

wires.
See continuation on - Check control module
Incorrect control module
next page version page 01-231 .
01-371

Scan Tool (ST)
DTC
00302
ABS solenoid valve relay -J106-
Voltage supply too low for ABS solenoid valve - Carry out "Electrical test", step
relay -J106- (terminal 30). 22 page 01-323 .
Continuation: ABS solenoid valve relay -J106- or ABS

hydraulic unit -N55- malfunctioning.
01-372

DTC
00526
Left brake light -M9- or right brake light - - Check the wiring. Carry out "Electrical
M10- malfunctioning. test", step 26 page 01-323 .
Open circuit
Open circuit in wiring between brake lights
and the ABS control module -J104-. Electrical Wiring Diagrams,
- Replace bulbs.
ABS control module -J104- malfunctioning - If the malfunction cannot be fixed,

replace the ABS control module -J104-.

Group 45
page
01-373

VAG1551 Scan Tool
(ST)
DTC
00526
Continuation:
Brake light switch -F- The brake light switch is not adjusted - Check brake light switch, "Read measuring
correctly. value block", display group 2 page 01-256
Implausible signal
Note: The brake light switch must be
adjusted exactly.
Open circuit/short circuit to B+ or Ground - Check wiring between brake light switch -F-
(GND) in wiring between brake light switch - and the ABS control module -J104-. Carry out
F- and the ABS control module -J104-. "Electrical test", step 26 page 01-323 .
Brake light switch malfunctioning. - If the malfunction cannot be fixed. replace

the brake light switch.
See continuation on
next page
Group 46
01-374

Scan Tool (ST)
DTC
00526
ABS control module -J104- - If the malfunction cannot be fixed, replace the
malfunctioning ABS control module -J104-.
Implausible signal
Continuation:
Master brake cylinder - Check the master brake cylinder, and replace if
malfunctioning. necessary.

Repair Group 47
Brake booster malfunctioning - Check the brake booster, and replace if

necessary.

Repair Group 47
01-375
Printed output from VAG1551 Scan Tool Possible cause Corrective action
(ST)
DTC
00532
Voltage supply Open circuit or resistance too high - "Read measuring value block"
between voltage supply of terminal 15 function 08 page 01-256 ,
This malfunction affects the voltage supply and ABS control module -J104- display group 6.
of the control module. (terminal 1).
This DTC is only stored, if it occurs the first Open circuit or resistance too high in step 21 page 01-323
time the vehicle exceeds 6 km/h. the Ground (GND) supply to ABS
As soon as the supply voltage is again control module -J104- (terminals 28 Electrical Wiring Diagrams,
within the valid voltage range, the system and 29). Troubleshooting & Component
is switched back on and the warning lights Voltage jumps in vehicle system. Locations
turn off.
See continuation on next page Voltage Regulator (VR).

Locations
- Check battery

Equipment, Repair Group 27,
Battery
01-376
Printed output from VAG1551 Scan Tool Possible cause Corrective action
(ST)
DTC
00532
Continuation:
Voltage supply
Open circuit or resistance too high - "Read measuring value block"
between voltage supply of terminal 15 function 08 page 01-256 ,
Signal too small and ABS control module -J104- display group 6.
(terminal 1).
This malfunction affects the voltage supply - Carry out "Electrical test",
of the control module. Open circuit or resistance too high in step 21 page 01-323
the Ground (GND) supply to ABS
This DTC is only stored, if it occurs the first control module -J104- (terminals 28 Electrical Wiring Diagrams,
time the vehicle exceeds 6 km/h. and 29). Troubleshooting & Component
As soon as the supply voltage is again Voltage jumps in vehicle system. Locations
within the valid voltage range, the system
is switched back on and the warning lights - Check Generator (GEN) and
turn off. Voltage Regulator (VR).

Locations
- Check battery

Equipment, Repair Group 27,
Battery
01-377

DTC
00597
Varying wheel speed
Wheel or tire sizes not the same on all four - Check wheel and tire sizes.
impulse wheels.
ABS wheel speed sensor rotor dirty or - Check rotor.

damaged.
Group 45
Excessive wheel bearing play. - Check wheel bearing


ABS wheel speed sensors -G44-, -G45-, -G46- - Check ABS wheel speed sensors.
, and -G47- installed incorrectly.
ABS wheel speed sensors -G44-, -G45-, -G46- Repair Manual, Brake System, Repair
, and -G47- malfunctioning Group 45
- Carry out "electrical test", steps 7

through 10 page 01-318 .
01-378

VAG1551 Scan Tool
(ST)
00778
Steering angle sensor - Open circuit or loose contact in data-BUS - Check fuses, wires and harness
G85- wires between steering angle sensor -G85- connectors as well as voltage supply to the
and ABS control module (w/EDL) -J104- control module: test step no. 13 page
no communication 01-323
Check specified values of: - Read measuring value block, function 08
page 01-256 , display group number 004
Steering angle sensor -G85-
Steering angle sensor -G85- malfunctioning - Replace steering angle sensor.

Group 45
- Code the ABS control module (w/EDL) -

J104- page 01-234
- Then perform zeroing procedure page
01-243
01-379

00778
Steering angle sensor - Steering angle sensor -G85- is not sending - Zero the steering angle sensor page
G85- adjustment values or is sending incorrect 01-243
values
Not adjusted or incorrectly
adjusted
00778
Steering angle sensor - The steering angle sensor -G85- is not - Check installed position of the steering
G85- installed correctly. angle sensor
Mechanical malfunction
Group 45
Vehicle alignment is not OK - Perform vehicle alignment.

Steering, Repair Group 44; Vehicle
alignment
Steering wheel was removed and zeroing - Then perform zeroing procedure page
was not performed afterward. 01-243
01-380

Scan Tool (ST)
00778
Steering angle sensor -G85- The steering angle sensor -G85- is - Check installed position of steering angle
not installed correctly. sensor -G85-
Implausible signal
Zero position calibration is not OK
Repair Manual, Brake System, Repair Group
45
Vehicle alignment is not OK - Perform vehicle alignment.

Repair Group 44; Vehicle alignment
- Then perform zeroing procedure page 01-

243
00778
Steering angle sensor -G85- Steering angle sensor -G85- is - Replace steering angle sensor.
malfunctioning
malfunctioning
45
- Then perform zeroing procedure page 01-

243
01-381

from VAG1551
Scan Tool (ST)
DTC
01044
Control module The ABS control module (w/EDL) - - Code the ABS control module (w/EDL) -J104- page
incorrectly coded J104- is either not coded or incorrectly 01-234
coded.
01119
Gear recognition Data is transferred between the ABS For more information, see the section titled "CAN-bus"
signal control module -J104- and the page 01-25 .
Transmission Control Module (TCM) via
the CAN-bus.
A DTC was stored in the Transmission - Check DTC memory of Transmission Control Module
Control Module (TCM). (TCM). Fix the malfunction according to the appropriate
Repair Manual and erase the DTC memory of the
Transmission Control Module (TCM).
01-382

VAG1551 Scan Tool
(ST)
DTC
01203
ABS / instrument Open circuit in wire from instrument - Check wires between instrument cluster
cluster electrical cluster combination processor -J218- to combination processor -J218- (green connector,
connection ABS control module -J104- terminal 11) and the ABS control module -J104-
(terminal 32).
Open circuit/short Short circuit to Ground (GND) in wire
circuit to Ground from instrument cluster combination
(GND) processor -J218- to ABS control module - Electrical Wiring Diagrams, Troubleshooting &
J104- Component Locations
See continuation on
next page
01-383

VAG1551 Scan Tool
(ST)
DTC
01203
ABS / instrument ABS control module - - For vehicles with automatic climate control: if wiring is OK, check the
cluster electrical J104- malfunctioning. TIM signal (standing time signal) with the ABS control module
connection connected and disconnected using the measuring value blocks for the
Note: Only replace the A/C control module -J301-. If the signal is recognized by the A/C
Open circuit/short control module -J301-, replace the ABS control module -J104-.
circuit to Ground control module as a last
(GND) resort.
Repair Manual, Heating & Air Conditioning, Repair Group 01
Continuation:
Instrument cluster - If the ABS control module -J104- still does not recognize the TIM
combinator processor - signal, replace the instrument cluster combination processor -J218-.
J218- malfunctioning.
See continuation
Note: Only replace the
on next page
control module as a last
resort.
01-384

VAG1551 Scan Tool
(ST)
DTC
01203
ABS / instrument cluster A/C control module - - If the TIM signal is also not recognized by the A/C control module
electrical connection J301- malfunctioning. -J301-, disconnect the A/C control module -J301- and check the
TIM signal by reading the measuring value blocks for the ABS
Open circuit/short circuit control module.
to Ground (GND) Note: Only replace the
control module as a last - "Read measuring value block" function 08 page 01-256
resort.
- If the signal is recognized by the ABS control module -J104- now,
replace the A/C control module -J301-.
Continuation:
See continuation on
next page
01-385

from VAG1551
Scan Tool (ST)
DTC
01203
Continuation:
ABS / instrument Short circuit to B+ in wire from - Check wires between instrument cluster combination processor
cluster electrical instrument cluster -J218- (green connector, terminal 11) and the ABS control
connection combination processor -J218- module -J104- (terminal 32).
to ABS control module -J104-
No signal
Electrical Wiring Diagrams, Troubleshooting & Component
Locations
ABS control module -J104- - For vehicles with automatic climate control: if wiring is OK,
malfunctioning. check the TIM signal (standing time signal) with the ABS control
module connected and disconnected using the measuring value
Note: Only replace the control blocks for the A/C control module -J301-. If the signal is
module as a last resort. recognized by the A/C control module -J301-, replace the ABS
Repair Manual, Heating & Air Conditioning, Repair Group 01
See continuation
on next page
01-386

VAG1551 Scan Tool
(ST)
DTC
01203
ABS / instrument A/C control module -J301- - If the TIM signal is also not recognized by the A/C control
cluster electrical malfunctioning. module -J301-, disconnect the A/C control module -J301- and
connection check the TIM signal by reading the measuring value blocks for
Note: Only replace the control the ABS control module.
No signal
module as a last resort. - "Read measuring value block" function 08 page 01-256
- If the signal is recognized by the ABS control module -J104-
now, replace the A/C control module -J301-.
Continuation:
Instrument cluster - If the ABS control module -J104- still does not recognize the
combinator processor - TIM signal, replace the instrument cluster combination
J218- malfunctioning. processor -J218-.
Note: Only replace the control

module as a last resort.
01-387

VAG1551 Scan Tool
(ST)
DTC
01314
Engine Control Module The Engine Control Module - Replace the ABS/ESP control module -J104- after
(ECM) (ECM) is not able to reduce conferring with the product department of your distributor
engine torque. or with the responsible importer.
Control difference
01316
Brake control module It took longer than 5 seconds for - Replace the ABS/ESP control module -J104- after
an ESP adjustment. conferring with the product department of your distributor
Control difference or with the responsible importer.
01-388

VAG1551 Scan Tool
(ST)
DTC
01418
Pilot valve -1- traction Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", step 5 page 01-
control -N225- in wiring between ABS hydraulic unit -N55- and 318 .
Pilot valve -1- traction control -N225- malfunctions, check all wiring and connectors
malfunctioning. for loose contacts.
- If the suggested steps do not lead to a
localization of the malfunction, replace the
ABS control module (w/EDL) -J104-.

Group 45
01419
Pilot valve -2- traction Open circuit, short circuit to B+ or Ground (GND) - Carry out "electrical test", step 5 page 01-
control -N226- in wiring between ABS hydraulic unit -N55- and 318 .
Pilot valve -2- traction control -N226- malfunctions, check all wiring and connectors
malfunctioning. for loose contacts.

Group 45
01-389

VAG1551 Scan Tool
(ST)
DTC
01420
High pressure switch Open circuit, short circuit to B+ or Ground - Carry out "electrical test", step 6 page
valve -1- traction (GND) in wiring between ABS hydraulic unit - 01-318 .
control -N227- N55- and ABS control module -J104-.
High pressure switch valve -1- traction control - malfunctions, check all wiring and
N227- malfunctioning. connectors for loose contacts.

Group 45
01421
High pressure switch Open circuit, short circuit to B+ or Ground - Carry out "electrical test", step 6 page
valve -2- traction (GND) in wiring between ABS hydraulic unit - 01-318 .
control -N228- N55- and ABS control module -J104-.
High pressure switch valve -2- traction control - malfunctions, check all wiring and
N228- malfunctioning. connectors for loose contacts.

Group 45
01-390

VAG1551 Scan Tool
(ST)
DTC
01422
Hydraulic pump for Insufficient voltage supply to hydraulic pump - Carry out "electrical test", step 25 page
traction control -V156- for traction control -V156-. 01-323 .
Short circuit to Ground (GND) in wiring - Check wiring between hydraulic pump for
between hydraulic pump for traction control - traction control -V156- and ABS control
V156- and ABS control module -J104-. module -J104- for short to Ground (GND).
Open circuit in voltage supply to ABS control - Check the voltage supply lines to ABS
module -J104-. control module -J104-.
Electrical Wiring Diagrams, Troubleshooting

Fuse malfunctioning. - Replace fuse 42.

See continuation on
next page Electrical Wiring Diagrams, Troubleshooting
01-391

VAG1551 Scan Tool
(ST)
DTC
01422
Hydraulic pump for Short circuit to Ground (GND) in - If you do not find a problem in wiring between hydraulic
traction control -V156- hydraulic pump for traction pump for traction control -V156- and ABS control module -
control -V156-. J104-, replace hydraulic pump for traction control -V156-.

Continuation:
ABS control module -J104- - If the malfunction cannot be fixed, replace the ABS
malfunctioning control module -J104-.
Note: Only replace the control Repair Manual, Brake System, Repair Group 45
See continuation on
next page
01-392

VAG1551 Scan Tool
(ST)
DTC
01422
Continuation:
Hydraulic pump for Open circuit in wiring between hydraulic - Check wiring between hydraulic pump for
traction control -V156- pump for traction control -V156- and ABS traction control -V156- and ABS control module
control module -J104-. -J104- for open circuit.
Short circuit to B+
Short circuit to B+ in wiring between - Check wiring between hydraulic pump for
hydraulic pump for traction control -V156- traction control -V156- and ABS control module
and ABS control module -J104-. -J104- for short to B+.
Electrical Wiring Diagrams, Troubleshooting

See continuation on
next page
01-393

VAG1551 Scan Tool
(ST)
DTC
01422
Hydraulic pump for Open circuit or short circuit to B+ - If you do not find a problem in wiring between hydraulic
traction control -V156- in hydraulic pump for traction pump for traction control -V156- and ABS control module -
control -V156-. J104-, replace hydraulic pump for traction control -V156-.
Short circuit to B+
Continuation:
See continuation on
next page
01-394

VAG1551 Scan Tool
(ST)
DTC
01422
Continuation:
Hydraulic pump for Short circuit to Ground (GND) in wiring - Check wiring between hydraulic pump for traction
traction control -V156- between hydraulic pump for traction control -V156- and ABS control module -J104- for
control -V156- and ABS control module short to Ground (GND).
Open circuit/short -J104-.
circuit to Ground
(GND) Electrical Wiring Diagrams, Troubleshooting &
Component Locations
Short circuit to Ground (GND) in - If you do not find a problem in wiring between
hydraulic pump for traction control - hydraulic pump for traction control -V156- and ABS
V156-. control module -J104-, replace hydraulic pump for
traction control -V156-.
Note: Only replace the control module as a Repair Manual, Brake System, Repair Group 45
last resort.
01-395

VAG1551 Scan Tool
(ST)
DTC WARNING!
This is only valid for control modules with no.: 4B0 907 389
01423
Sensor for transverse Sensor for transverse acceleration - - Check the installation position of the sensor for
acceleration -G200-
G200- not installed correctly. transverse acceleration -G200-.
There is an open circuit in one of the - Check Ground (GND) between sensor for
supply wires for the sensor for transverse acceleration -G200 (terminal 1) and ABS
transverse acceleration -G200-. control module -J104- (terminal 19).
- Check voltage supply between sensor for
transverse acceleration -G200 (terminal 3) and -
J104- ABS control module (terminal 75).

Component Locations
See continuation on
next page
01-396

VAG1551 Scan Tool
(ST)
DTC WARNING!
01423
Sensor for transverse Open circuit in signal line to sensor for - Check signal line between sensor for transverse
acceleration -G200-
transverse acceleration -G200-. acceleration -G200 (terminal 2) and ABS control
module -J104- (terminal 18).
Short circuit to B+ or Ground (GND) in
signal line to sensor for transverse
acceleration -G200-. Electrical Wiring Diagrams, Troubleshooting &
Continuation:
Component Locations
Sensor for transverse acceleration - - If none of the causes listed are causing the
G200- malfunctioning. malfunction, replace sensor for transverse
acceleration -G200-.
See continuation on
last resort.
next page
01-397

VAG1551 Scan Tool
(ST)
DTC WARNING!
This is only valid for control modules with no.: 8D0 907 389, 8D0 907 389A, 8D0 907 389D
and 8D0 907 389E.
01423
Sensor for transverse Sensor for transverse acceleration - - Check the installation position of the sensor for
acceleration -G200- G200- not installed correctly. transverse acceleration -G200-.
There is an open circuit in one of the - Check Ground (GND) between sensor for
supply wires for the sensor for transverse acceleration -G200 (terminal 1) and ABS
transverse acceleration -G200-. control module -J104- (terminal 69).

Component Locations
See continuation on
next page
01-398

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01423
acceleration -G200- transverse acceleration -G200-. acceleration -G200 (terminal 2) and ABS control
Continuation:
Component Locations
See continuation on
last resort.
next page
01-399

VAG1551 Scan Tool
(ST)
DTC WARNING!
01423
acceleration -G200-
Failure in electrical Short circuit to B+ or Ground (GND) in
circuit signal line to sensor for transverse
Component Locations
Continuation:

See continuation on
next page
01-400

VAG1551 Scan Tool
(ST)
DTC WARNING!
01423
Continuation:
Sensor for transverse There is an open circuit in one of the - Check Ground (GND) between sensor for
acceleration -G200- supply wires for the sensor for transverse acceleration -G200 (terminal 1) and
transverse acceleration -G200-. ABS control module -J104- (terminal 19).
Failure in electrical
circuit - Check voltage supply between sensor for

Component Locations
last resort.
See continuation on
next page
01-401

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01423
acceleration -G200- transverse acceleration -G200-. acceleration -G200 (terminal 2) and ABS control
Failure in electrical Short circuit to B+ or Ground (GND) in
circuit signal line to sensor for transverse
Component Locations
Continuation:

See continuation on
next page
01-402

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01423
Failure in electrical
circuit - Check voltage supply between sensor for
Continuation: Electrical Wiring Diagrams, Troubleshooting &

Component Locations
last resort.
See continuation on
next page
01-403

VAG1551 Scan Tool
(ST)
DTC
01423
Continuation: Note:
Sensor for The input signals received by ABS control module -J104- are analyzed by computing programs and
transverse checked for plausibility. If the sensor for transverse acceleration -G200- fails, the relevant computing
acceleration -G200- program relies primarily on the steering angle sensor -G85-. If you think there is a problem with the
sensor for transverse acceleration -G200-, check whether the steering angle sensor -G85- is OK.
Implausible signal The steering angle sensor must also be checked.
- While driving straight ahead (v < 20 km/h), check the zero position of the steering angle sensor -
G85-, by selecting "Read measuring value block", function 08 page 01-256 , display group 5
page 01-270 .
- Check the sensor for transverse acceleration -G200- as described in the instructions for "Read
measuring value block" function 08 page 01-270 , display group 5, page 01-270 .
See continuation on There are four possibilities:
next page
01-404

DTC
01423
Sensor for transverse First:
acceleration -G200-
The zero position of steering angle sensor -G85- is not within the specified range, and the
Implausible signal zero position of sensor for transverse acceleration -G200- is within the specified range:
Continuation:
- Then perform zeroing procedure page 01-243

- Erase DTC memory page 01-15
- Road test vehicle page 01-250
- If the malfunction occurs again, follow the procedure for the second
case.

page
01-405

VAG1551 Scan Tool
(ST)
DTC WARNING!
01423
Sensor for transverse Second:
acceleration -G200-
The zero position of steering angle sensor -G85- is within the specified range, and the zero
Implausible signal position of sensor for transverse acceleration -G200- is not within the specified range:
Continuation:
Open circuit in signal line to sensor for - Check signal line between sensor for transverse
Component Locations
See continuation on
last resort.
next page
01-406

VAG1551 Scan Tool
(ST)
DTC WARNING!
01423
acceleration -G200-
supply wires for the sensor for transverse acceleration -G200 (terminal 1) and
Implausible signal
Continuation:
(Second) Electrical Wiring Diagrams, Troubleshooting &
Component Locations
If none of the causes fit:
Sensor for transverse acceleration -
G200- malfunctioning.
- If malfunction occurs again, replace sensor for
transverse acceleration -G200-.
See continuation on
next page
01-407

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01423
Sensor for transverse Second:
acceleration -G200-
The zero position of steering angle sensor -G85- is within the specified range, and the zero position
Implausible signal of sensor for transverse acceleration -G200- is not within the specified range:
Continuation:
There is an open circuit in one of the signal - Check the signal wire for the combined sensor
wires for the combined sensor for rotation for rotation rate and transverse acceleration,
rate and transverse acceleration. terminal 4, to the ABS control module -J104-
(terminal 18).
There is short circuit to B+ or Ground (GND)
in one of the signal wires for the combined
sensor for rotation rate and transverse Electrical Wiring Diagrams, Troubleshooting &
acceleration. Component Locations
ABS control module -J104- malfunctioning - If the malfunction cannot be fixed, replace the
Note: Only replace the control module as a last
resort. Repair Manual, Brake System, Repair Group
See continuation on
45
next page
01-408

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01423
Implausible signal
Continuation:
(Second) Electrical Wiring Diagrams, Troubleshooting &
Component Locations
If none of the causes fit:
Sensor for transverse acceleration -
See continuation on
next page
01-409

DTC
01423
Sensor for transverse Third:
acceleration -G200-
The zero position of steering angle sensor -G85- is not within the specified range, and the
Implausible signal zero position of sensor for transverse acceleration -G200- is not within the specified range:
Continuation:
- Follow the procedures from the first and second cases.

page
01-410

DTC
01423
Sensor for transverse Fourth:
acceleration -G200-
Implausible signal position of sensor for transverse acceleration -G200- is within the specified range:
Continuation:
Sensor for transverse acceleration - - Erase DTC memory page 01-15


45
Note: Only replace the control module as Repair Manual, Brake System, Repair Group
a last resort. 45
01-411

VAG1551 Scan Tool
(ST)
DTC WARNING!
01424 For control modules 4B0 907 389, the VAG1551 scan tool with test card 7 and the VAG1552
scan tool with test card 4 display the following incorrect text: "Sender for rotation rate -G202-,
reference wire".
Sender for rotation rate - Open circuit in signal wire of sender for - Check signal line between yaw sensor -G202-
G202-, signal wire
rotation rate -G202-. (terminal 3) and ABS control module -J104-
(terminal 79).
Failure in electrical circuit Short circuit to B+ or Ground (GND) in
signal wire to sender for rotation rate -
G202-. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
Sender for rotation rate -G202- - If none of the causes listed are causing the
malfunctioning. malfunction, replace yaw sensor -G202-.

See continuation on
45
next page
01-412

DTC WARNING!
reference wire".
Sender for rotation rate -
Open circuit in supply line to - Check Ground (GND) between yaw sensor -G202-
G202-, signal wire
yaw sensor -G202-. (terminal 1) and ABS control module -J104- (terminal 80).
Failure in electrical circuit - Check voltage supply between yaw sensor -G202-
(terminal 2) and ABS control module -J104- (terminal 34).

Continuation: Component Locations
01-413

DTC WARNING!
and 8D0 907 389E.
Continuation: For control modules 8D0 907 389/A/D/E, the VAG1551 scan tool with test card 8 and the
VAG1552 scan tool with test card 5 display the following incorrect text: "Sender for rotation rate
-G202-, signal wire".
01424
Yaw sensor -G202-,
Open circuit in reference wire of - Check reference line between yaw sensor -G202-
reference line sender for rotation rate -G202-. (terminal 4) and ABS control module -J104- (terminal
78).
Failure in electrical circuit Short circuit to B+ or Ground (GND)
in reference line to yaw sensor -
Component Locations
Note:
The reference line of yaw sensor -G202- carries the reference signal. The reference signal
corresponds to the signal the sensor sends to the ABS control module -J104- when the vehicle
is traveling straight ahead.
01-414

VAG1551 Scan Tool
(ST)
DTC WARNING!
scan tool with test card 4 display the following incorrect text: "Sender for rotation rate -
G202-, signal wire".
Yaw sensor -G202-,
Open circuit in reference wire of - Check reference line between yaw sensor -G202-
reference line
sender for rotation rate -G202-. (terminal 4) and ABS control module -J104- (terminal
78).
Failure in electrical Short circuit to B+ or Ground (GND)
circuit in reference line to yaw sensor -
Component Locations
Note:
The reference line of yaw sensor -G202- carries the reference signal. The reference signal
corresponds to the signal the sensor sends to the ABS control module -J104- when the vehicle is
traveling straight ahead.
01-415

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
Continuation: For control modules 8D0 907 389/A/D/E, the VAG1551 scan tool with test card 8 and the VAG1552
reference wire".
01425
Sender for rotation rate There is an open circuit in one of the signal - Check the signal wire for the combined sensor
-G202-, signal wire wires for the combined sensor for rotation for rotation rate and transverse acceleration,
Failure in electrical (terminal 79).
circuit There is short circuit to B+ or Ground (GND)
Sender for rotation rate -G202- - If none of the causes listed are causing the
malfunctioning. malfunction, replace yaw sensor -G202-.

See continuation on
45
next page
01-416

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01425 For control modules 8D0 907 389/A/D/E, the VAG1551 scan tool with test card 8 and the
VAG1552 scan tool with test card 5 display the following incorrect text: "Sender for rotation rate
-G202-, reference wire".
Sender for rotation rate - Open circuit in supply line to - Check Ground (GND) between yaw sensor -G202-
G202-, signal wire yaw sensor -G202-. (terminal 1) and ABS control module -J104- (terminal 80).
Failure in electrical circuit - Check voltage supply between yaw sensor -G202-

Continuation: Component Locations
01-417

VAG1551 Scan Tool
(ST)
DTC
01435
Sender 1 for brake The brake light switch is not adjusted - Check the installation position of the brake light
booster -G201- correctly or is not installed correctly. switch.
- Check brake light switch -F-, "Read measuring

value block" function 08 page 01-256 , display
group 2
- Check sensor for brake pressure -G201-, "Read
measuring value block" function 08 page 01-256 ,
display group 5
Open circuit in signal wire of sender - Check signal line between sensor for brake
1 for brake booster -G201-. pressure -G201- (terminal 2) and ABS control
Short circuit to B+ or Ground (GND)
in signal wire to sender 1 for brake
booster -G201-. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
See continuation on
next page
01-418

VAG1551 Scan Tool
(ST)
DTC
01435
Sender 1 for brake Sensor for brake pressure -G201- - If none of the causes listed are causing the
booster -G201- malfunctioning. malfunction, replace hydraulic pump for traction control
V-156- and sensor for brake pressure -G201-.

Continuation:
- Bleed brake system.
Open circuit in one of the voltage - Check Ground (GND) between sensor for brake
supply wires to sensor for brake pressure -G201- (terminal 1) and ABS control module -
pressure -G201-. J104- (terminal 67).
- Check voltage supply between sensor for brake
pressure -G201- (terminal 3) and ABS control module -
J104- (terminal 69).

Component Locations
See continuation on
next page
01-419

Scan Tool (ST)
DTC
01435
Sender 1 for brake booster -
G201- malfunctioning ABS control module -J104-.
Note: Only replace the control module Repair Manual, Brake System, Repair Group
as a last resort. 45
Continuation:
01-420

VAG1551 Scan Tool
(ST)
DTC
01435
Continuation:
Sender 1 for brake booster Open circuit in signal wire of sender - Check signal line between sensor for brake
-G201- 1 for brake booster -G201-. pressure -G201- (terminal 2) and ABS control
Failure in electrical circuit Short circuit to B+ or Ground (GND)
in signal wire to sender 1 for brake
booster -G201-. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
Open circuit in one of the voltage - Check Ground (GND) between sensor for brake
supply wires to sensor for brake pressure -G201- (terminal 1) and ABS control
pressure -G201-. module -J104- (terminal 67).
- Check voltage supply between sensor for brake
pressure -G201- (terminal 3) and ABS control

Component Locations

page
01-421

DTC
01435
Sender 1 for brake booster
Sensor for brake pressure - - If none of the causes listed are causing the malfunction,
-G201- G201- malfunctioning. replace hydraulic pump for traction control V-156- and
sensor for brake pressure -G201-.
Failure in electrical circuit
Continuation: - Bleed brake system.
ABS control module -J104- - If the malfunction cannot be fixed, replace the ABS control
malfunctioning module -J104-.
page
01-422

VAG1551 Scan Tool
(ST)
DTC
01435
Continuation:
Sender 1 for brake The hydraulic pump for traction control -V156- was - Erase DTC memory page 01-15
booster -G201- switched on but is not producing more than 2 bar
and less than 30 bar of pressure in the master - End Output page 01-16 .
Implausible signal brake cylinder. - Road test vehicle page 01-250
- If malfunction occurs again, replace
hydraulic pump for traction control -
V156- and sensor for transverse

Group 45
- Bleed brake system.

Group 47
01435
Sender 1 for brake
Master brake cylinder malfunctioning. - Check the master brake cylinder, and
booster -G201- replace if necessary.

Implausible signal
Group 47
Brake booster malfunctioning - Check the brake booster, and replace if

necessary.

Group 47
01-423

DTC
01435
Continuation:
Sender 1 for brake booster
Voltage supply has a short circuit - Check Ground (GND) between sensor for brake
-G201- to B+. pressure -G201- (terminal 1) and ABS control module
-J104- (terminal 67).
- voltage supply Voltage supply has a short circuit
to Ground (GND). - Check voltage supply between sensor for brake
pressure -G201- (terminal 3) and ABS control module
Open circuit in one of the voltage -J104- (terminal 69).
supply wires to sensor for brake
pressure -G201-.
Component Locations
01-424

VAG1551 Scan Tool
(ST)
DTC
01464 If this malfunction is recognized by On Board Diagnostic (OBD), then the voltage supply of sender
1 for brake booster -G201- was not distinguished from the voltage supply for the sensor for
transverse acceleration -G200-. Check both components and their wiring.
Brake pressure Insufficient voltage supply for - Check the voltage supply lines from the sensor for brake
sensor/lateral sender 1 for brake booster - pressure -G201- (terminal 3) to the ABS control module -J104-
acceleration sensor G201-. (terminal 69) for a short circuit to Ground (GND) or B+.
Voltage supply
Insufficient voltage supply to - Check the voltage supply lines from the sensor for transverse
sensor for transverse acceleration -G200- (terminal 3) to the ABS control module -
acceleration -G200-. J104- (terminal 75) for a short circuit to Ground (GND) or B+.
See continuation on
next page
01-425

VAG1551 Scan Tool
(ST)
DTC
01464 If this malfunction is recognized by On Board Diagnostic (OBD), then the voltage supply of
sender 1 for brake booster -G201- was not distinguished from the voltage supply for the sensor
for transverse acceleration -G200-. Check both components and their wiring.
Brake pressure If you do not find any malfunctions in the voltage supply
One of the two sensors is
sensor/lateral lines, then:
malfunctioning.
acceleration sensor
Voltage supply
- Ignition off
Continuation: - Disconnect one sensor and then the other.
- Replace the sensor for which the DTC is no longer
recognized after the ignition is switched on.
Note: Only replace the control module Repair Manual, Brake System, Repair Group 45
as a last resort.
01-426
Printed output from VAG1551 Scan Possible cause Corrective action

Tool (ST)
DTC WARNING!
This DTC is not included in the VAG1551/1552 scan tools

01486
System function test activated
The ESP driving test was - Perform entire ESP driving and system test
activated page 01-250
01-427

from VAG1551
Scan Tool (ST)
DTC
01542
Sender for The input signals received by ABS control module -J104- are analyzed by computing programs and
rotation rate - checked for plausibility. If the sender for rotation rate -G202- fails, the relevant computing program relies
G202- primarily on the steering angle sensor -G85- and the sensor for transverse acceleration -G200-. If you
think there is a problem with the sender for rotation rate -G202-, check whether the steering angle
Implausible sensor -G85- and sensor for transverse acceleration -G200- are OK. These must also be checked.
signal
- While driving straight ahead (v < 20 km/h), check the zero position of the steering angle sensor -G85-,
by selecting display group 5 in "Read measuring value block", function 08 page 01-256 .
- Check the sensor for transverse acceleration -G200- as described in the instructions for "Read
measuring value block" function 08 page 01-270 , display group 5.
See continuation There are four possibilities:
on next page
01-428

Scan Tool (ST)
DTC
01542
Sender for rotation rate -G202- First: (Also note the fourth possibility)
Implausible signal The zero position of steering angle sensor -G85- is not within the specified range, and the
zero position of yaw sensor -G202- is within the specified range:
Continuation:
- Perform zeroing. page 01-243

page - If the malfunction occurs again, follow the procedure for the second
case.
01-429

DTC WARNING!
01542
Sender for rotation rate - Second: (Also note the fourth possibility)
G202-
Implausible signal position of yaw sensor -G202- is not within the specified range:
Continuation:
Open circuit in signal wire of sender - Check signal line between yaw sensor -G202-
for rotation rate -G202-. (terminal 3) and ABS control module -J104-
(terminal 79).
in signal wire to sender for rotation
rate -G202-. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
page
01-430

DTC WARNING!
01542
Sender for rotation rate -
Open circuit in supply line - Check Ground (GND) between yaw sensor -G202-
G202-
to yaw sensor -G202-. (terminal 1) and ABS control module -J104- (terminal 80).
Implausible signal - Check voltage supply between yaw sensor -G202-

Continuation: (Second) Component Locations

page
01-431

Scan Tool (ST)
DTC
01542
Sender for rotation rate -G202- If none of the causes fit:
malfunctioning.
Implausible signal - Erase DTC memory page 01-15
Continuation: (Second)
- If malfunction occurs again, replace yaw
sensor -G202-.

45
01-432

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01542
Sender for rotation rate Second: (Also note the fourth possibility)
-G202-
The zero position of steering angle sensor -G85- is within the specified range, and the zero position
Implausible signal of the sensor for transverse acceleration -G200-, or the combined sensor for rotation rate and
transverse acceleration, is not within the specified range:
Continuation:
There is an open circuit in one of the signal - Check the signal wire for the combined sensor
wires for the combined sensor for rotation for rotation rate and transverse acceleration,
(terminal 18).
There is short circuit to B+ or Ground
(GND) in one of the signal wires for the
combined sensor for rotation rate and Electrical Wiring Diagrams, Troubleshooting &
transverse acceleration. Component Locations
01-433

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01542
Sender for rotation There is an open circuit in one of the - Check the Ground (GND) supply for the combined
rate -G202- voltage supply wires for the combined sensor for rotation rate and transverse acceleration,
sensor for rotation rate and transverse terminal 2, to the ABS control module -J104-
Implausible signal acceleration. (terminal 80).
- Check the voltage supply of the combined sensor
for rotation rate and transverse acceleration,
Continuation: terminal 1, to the ABS control module -J104-
(Second) (terminal 34).

Component Locations
See continuation on
next page
01-434

DTC WARNING!
This is only valid for control modules with no.: 8D0 907 389, 8D0 907 389A, 8D0 907
389D and 8D0 907 389E.
01542
Sender for rotation rate - If none of the causes fit:
The combined sensor for rotation rate
G202-
and transverse acceleration is
malfunctioning. - Erase DTC memory page 01-15
Implausible signal
Continuation: (Second) - If malfunction occurs again, replace
combined sensor for rotation rate and
transverse acceleration.

Group 45
ABS control module -J104- - If the malfunction cannot be fixed, replace

malfunctioning the ABS control module -J104-.
Note: Only replace the control module as a Repair Manual, Brake System, Repair
last resort. Group 45
page
01-435

VAG1551 Scan Tool
(ST)
DTC
01542
Sender for rotation rate - Third: (Also note the fourth possibility)
G202-
The zero position of steering angle sensor -G85- is not within the specified range, and the zero
Implausible signal position of the sensor for transverse acceleration -G200-, or the combined sensor for rotation
rate and transverse acceleration, is not within the specified range:
Continuation:
- Follow the procedures from the first and second possibilities.

See continuation on
next page
01-436

DTC WARNING!
01542
Sender for rotation rate - Fourth:
G202-
Implausible signal position of sensor for transverse acceleration -G200- is within the specified range:
Continuation:
- Check the sender for rotation rate -G202- by selecting the "Read measuring value block"
function 08 page 01-256 , display group 5,
The yaw sensor -G202- is loose. - Check bolts for yaw sensor -G202-.
Open circuit in signal wire of sender - Check signal line between yaw sensor -G202-
for rotation rate -G202-. (terminal 3) and ABS control module -J104-
(terminal 79).
in signal wire to sender for rotation
rate -G202-. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
page
01-437

VAG1551 Scan Tool
(ST)
DTC WARNING!
01542
Sender for rotation rate Open circuit in supply line to - Check Ground (GND) between yaw sensor -G202- (terminal
-G202-
yaw sensor -G202-. 1) and ABS control module -J104- (terminal 80).
Implausible signal
Continuation: - Check voltage supply between yaw sensor -G202- (terminal
(Fourth) 2) and ABS control module -J104- (terminal 34). Electrical
Wiring Diagrams, Troubleshooting & Component Locations
Open circuit in test lead of - Check test line between yaw sensor -G202- (terminal 5) and
sender for rotation rate - ABS control module -J104- (terminal 77).
G202-.
Short circuit to B+ or Ground Electrical Wiring Diagrams, Troubleshooting & Component
(GND) in test lead of sender Locations
See continuation on for rotation rate -G202-.
next page
01-438

Scan Tool (ST)
DTC WARNING!
01542
Sender for rotation rate -G202- If none of the causes fit:
malfunctioning.
Implausible signal - Erase DTC memory page 01-15
Continuation: (Fourth)
- If malfunction occurs again, replace yaw
sensor -G202-.

45
01-439

DTC WARNING!
This is only valid for control modules with no.: 8D0 907 389, 8D0 907 389A, 8D0 907
389D and 8D0 907 389E.
01542
Sender for rotation rate - Fourth:
G202-
Implausible signal position of the combined sensor for rotation rate and transverse acceleration is within the
specified range:
Continuation:
- Check the combined sensor for rotation rate and transverse acceleration by selecting "Read
measuring value block" function 08 page 01-256 , display group 5
The combined sensor for rotation rate and - Check bolts for combined sensor for
transverse acceleration is loose. rotation rate and transverse acceleration.

Group 45
page
01-440

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01542
Sender for rotation There is an open circuit in one of the - Check the Ground (GND) supply for the combined
rate -G202- voltage supply wires for the combined sensor for rotation rate and transverse acceleration,
sensor for rotation rate and transverse terminal 2, to the ABS control module -J104-
Implausible signal acceleration. (terminal 80).
- Check the voltage supply of the combined sensor
for rotation rate and transverse acceleration,
Continuation: terminal 1, to the ABS control module -J104-
(Fourth) (terminal 34).

Component Locations
See continuation on
next page
01-441

VAG1551 Scan Tool
(ST)
DTC WARNING!
and 8D0 907 389E.
01542
Sender for rotation There is an open circuit in one of the signal - Check the signal wire for the combined sensor
rate -G202- wires for the combined sensor for rotation for rotation rate and transverse acceleration,
Implausible signal (terminal 79).
Continuation:
(Fourth)
There is an open circuit in the test lead of - Check the test lead of the combined sensor for
the combined sensor for rotation rate and rotation rate and transverse acceleration,
transverse acceleration. terminal 3, to the ABS control module -J104-
(terminal 77).
in the test lead of the combined sensor for
rotation rate and transverse acceleration. Electrical Wiring Diagrams, Troubleshooting &
Component Locations
See continuation on
next page
01-442

Scan Tool (ST)
DTC WARNING!
This is only valid for control modules with no.: 8D0 907 389, 8D0 907 389A, 8D0
907 389D and 8D0 907 389E.
01542
Engine overview Page 1 of 6
Engine overview
Code Letters AFC AEB APB AHA ATQ
Manufactured from 11.94 11.94 09.99 02.97
Cylinders / valves per cylinder 6/2 4/5 6/5 6/5 6/5
Capacity liters 2.771 1.781 2.671 2.771 2.771
Output kW / rpm 128 / 5500 110 / 5700 187 / 5800 142 / 6000 142 / 6000
Torque Nm / rpm 245 / 3000 210 / 1750 258 / 280 / / 3200 280 / / 3200
250 / 30001) 1800-4500
Bore dia. - mm 82.5 81.0 81.0 82.5 82.5

Stroke mm 86.4 86.4 86.4 86.4 86.4
Compression ratio 10.3:1 9.5:1 9.3:1 10.6:1 9.9:1
Hyd. valve lifters Yes Yes Yes Yes Yes
Fuel and Ignition System Multi-Point Injection Motronic Motronic Motronic Motronic
Octane min. 95 2) 95 98 3) 983)
1) If unleaded premium plus 98 octane is used.
2) Unleaded premium plus 98 octane is also approved.
3) Unleaded 95 octane is also approved, though it yields less power.
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.ME01.01.1 11/20/2002
Code Letters AFC AEB APB AHA ATQ

Exhaust Gas Yes No No No No
Recirculation (EGR)
OBD with DTC Memory Yes Yes Yes Yes Yes
Exhaust emission control Three Way Catalytic Converter (TWC)
Oxygen Sensor (O2S) Control Yes Yes Yes Yes Yes
Electronic throttle control (E-Gas) No No Yes
Variable valve timing No No Yes
Overview of Oil Changes and Maintenance to my 2001
Service intervals in miles (kilometers)
5,000 miles (8,000 km)1)Oil Change and Maintenance Service
40,000 miles (64,000 km)Oil Change and Maintenance Service

The brake fluid must be replaced every 2 years regardless of mileage (kilometers)
1) or 6 months after delivery, whichever occurs first.
2) or 12 months after delivery, whichever occurs first.
3) or 12 months after the least Maintenance Service, whichever occurs first.
The intervals shown in this table are based on

vehicles operating under normal conditions. In
case of severe conditions, such as extremely low
temperatures, excessive dust, etc., it is
necessary for certain operations to be carried out
in between the given intervals. This applies
particularly to engine oil changes and the
cleaning or replacing of the air cleaner filter
element.
Overview of Oil Changes and Maintenance from my 2002
Service intervals in miles (kilometers)

The brake fluid must be replaced every 2 years regardless of mileage (kilometers)
1) Maintenance at 10,000 miles (15,000 km) or 1 year after delivery, whichever occurs first.
2) Maintenance at 20,000 miles (30,000 km) or 2 years after delivery, whichever occurs first.
The intervals shown in this table are based on

vehicles operating under normal conditions. In
case of severe conditions, such as extremely low

temperatures, excessive dust, etc., it is
necessary for certain operations to be carried out
in between the given intervals. This applies
particularly to engine oil changes and the
cleaning or replacing of the air cleaner filter
element.
Description of systems Page 1 of 10
01-35
Description of systems
The individual components have the
following functions:
ABS
Anti-lock Brake System
ABS prevents the wheel from locking up during

hard braking initiated by the driver. Despite high
brake effectiveness, lane stability and steering
capacity are maintained.
01-36
EBD
Electronic Brake Distribution
Specialized software stored in the ABS control

module -J104-, called Electronic Brake
Distribution (EBD), assumes the function of the
brake pressure regulator.
The signal sent to the instrument cluster when

ABS fails is pulsed if the EBD function remains
operational in emergency mode. The instrument
cluster distinguishes between no signal, a pulsed
signal, and a steady signal. The ABS/EDL
indicator lamp and the red symbol for "Brake
system malfunction" will light up accordingly.
01-37
1 - Terminal 15
2 - Signal for controlling the ABS/EDL indicator lamp and the red "brake
system malfunction" symbol.
3 - Voltage supply for the ABS/EDL indicator lamp.
4 - Voltage supply for the red "brake system malfunction" symbol.
A - In interval "A" (with "ignition on") a self-test of the ABS/EDL indicator
lamp is carry outed for two seconds using signal "2" (lamp lights up).
During this interval, the instrument cluster suppresses the red "brake
system malfunction" symbol.
B - Signal "2" is not available in interval "B". The ABS/EDL indicator lamp
and the red "brake system malfunction" symbol do not light.
C - In interval "C", the On Board Diagnostic recognized a DTC, which did
not deactivate the EBD. Signal "2" is pulsed. Only the ABS/EDL indicator
lamp comes on.
D - In interval "D", the On Board Diagnostic recognized a DTC, which did
deactivate the EBD. Signal "2" is steady. Both the ABS/EDL indicator
lamp and the red "brake system malfunction" symbol light up.
01-38
The red "brake system malfunction" symbol

indicates the EBD is deactivated. The vehicle
is only allowed to be driven under restricted
conditions; "Road test vehicle".
For additional information about EBD indicator

lamp control, see: "Overview of warning lamp
functions"; The vehicle version as relates to EBD
can be recognized by checking the note column
under "Check control module version".
01-39
EDL
Electronic Differential Lock
The Electronic Differential Lock (EDL) is a

traction control aid for driving away from a
standstill. An electronically-controlled brake
application at the wheel that is spinning provides
a torque reaction point for the differential. This
enables the wheel with better traction to make
use of the engine power. EDL is effective in both
forward and reverse.
EDL is part of the basic configuration of vehicles

with All Wheel Drive (AWD). Although EDL only
regulates the front wheels on vehicles with Front
Wheel Drive (FWD), EDL regulates all four
wheels on vehicles with All Wheel Drive (AWD).
This makes it possible to eliminate the driver
operated mechanical differential lock.
01-40
Onset of EDL regulation is permitted up to a

speed of 40 km/h. The upper switch-off barrier
for already active EDL is 40 km/h for vehicles
with Front Wheel Drive (FWD), but 80 km/h for
vehicles with All Wheel Drive (AWD).
The hydraulic unit is equipped with suction

dampers. They improve pressure build-up in the
appropriate brake cylinders during EDL
regulation. The functional range of the pressure
relief valve in the hydraulic unit is 170 25 bar.
To reduce the risk of brake overheating, EDL

regulation is not permitted above a specific brake
temperature. The temperature limit is defined in
the ABS control module (w/EDL) -J104-. The
control module determines the actual brake
temperature via an algorithm. If the algorithm
determines that the brakes have reached a
temperature below the temperature limit, the EDL
system becomes effective again. Function of the
vehicle brake system and ABS are not affected
by intervention in this system.
01-41
When ignition is switched off, the temperature

calculated for the hot brakes is stored until
ignition is switched on again. When ignition is
switched on, the instrument cluster transmits a
time signal so that the ABS control module
(w/EDL) -J104- can calculate the standing time.
This standing time is required by the temperature
algorithm for calculation of the new brake
temperature. If the indicated standing time
exceeds one hour, the brake temperature is
automatically set to the lowest temperature in the
temperature algorithm.
EDL shut-off for temperature reasons is indicated

in the measuring value block for a period of 20
ignition cycles.
01-42
ASR
Anti-Slip Regulation (ASR)
The ASR option is only available on Front Wheel

Drive (FWD) vehicles. Observe control module
coding for these vehicles. The function of ASR
requires an exchange of signals between the
ABS control module -J104-, the Engine Control
Module (ECM) and the Transmission Control
Module (TCM). The control modules
communicate with each other.
There are two communication systems at work:
- Data is transferred via several single wires.
- Data is transferred via the CAN-bus. The

CAN-bus only contains two lines. These
transfer all required data.
To determine which communication system is

transferring data, use the "Check control module
version" function and check the table "Control
module versions".
01-43
ASR prevents the wheels being powered from

spinning during acceleration by reducing engine
load. It is active throughout the entire speed
range. The EDL and ASR functions work in
combination during vehicle acceleration.
ASR can be switched on and off by pressing the

traction control button in the center of the center
console. ASR is re-activated on its own when the
ignition is switched on. When the traction control
button is operated, the ASR indicator lamp lights
up in the instrument cluster. During adjustment
mode, the indicator lamp blinks three times per
second.
01-44
ESP
Electronic Stabilization Program (ESP)
The Electronic Stabilization Program (ESP) is a

driving dynamics regulation system. It stabilizes
the vehicle both in understeer and oversteer
situations. ESP regulation includes the functions
of EBD, ABS, EDL and ASR. A special function
of ESP is that it can brake individual wheels.
ESP includes the functions of EBD, ABS, EDL

and ASR. The individual components have
the following functions:
The ASR and ESP functions can be switched on

and off using the ASR/ESP switch on the center
console. If the driver steps on the brake pedal,
the status of the ESP switch is ignored. When
braking, ESP is always active. When the ignition
is switched on, the ASR and ESP functions are
activated.
When switched off, the ASR/ESP indicator light

is lit up in the instrument cluster. During
adjustment mode, the indicator lamp blinks three
times per second.
Cruise control On Board Diagnostic (OBD) Page 1 of 13
01-203
Cruise control On Board

Diagnostic (OBD)
Special tools, test equipment and auxiliary
items
VAS5051 Diagnostic Operation Center (DOC)

and/or VAG1551 Scan Tool (ST).
01-204
Gasoline engines with electronically-

operated throttle valve only
Testing cruise control system
- Connect VAG1551 scan tool ( Page 01-241 )

and use "Address word 01" to select engine
control module.
The engine should be idling.
Except for the control lever, there are no system

components for the cruise control system. All
functions are carried out by the engine control
module.
Initiating "Read Measuring Value Block" scan

tool function 08

Select function XX
function 08.
01-205


- Enter display group number 066.
The engine should be idling.
The measured value block which has been selected will appear in the
standard format.
Display group overview
Display group Display fields

number
066 1 Actual vehicle speed km/h
=
2 Switch positions of brake, clutch and cruise
= control (open or closed)
3 Desired vehicle speed km/h
=
4 Control lever switch positions
=
01-206
Display group 066

km/h XXXX km/h XXXX
Control lever switch positions
0 0 0 0 = Cruise control off (switch engaged)
0 0 1 1 = Cruise control on
0 0 0 1 = Cruise control off before engagement position
0 1 1 1 = Fix button pushed
1 0 1 1 = Record button pulled

Desired vehicle speed (speed last saved is displayed until):
Cruise control is switched off at control lever, i.e. switch is engaged on "OFF" or
Engine is stopped.
Switch positions for brakes, clutch and cruise control released.
1 0 0 0 = Cruise control released
1 0 1 1 = Brake applied (brake pedal switch)
1 1 0 0 = Clutch applied
Actual vehicle speed
01-207

0 km/h 1000 0km/h 0000
Checking displays in display fields 2 and 4
Read Measuring Value Block 66 Display check, display field 2

0 km/h 1000 0km/h 0000
Test conditions Display field 2
Cruise control released (activated) 1000
Brake applied (brake pedal switch) 1011
Clutch applied 1100
If the nominal value in display field 2 for "cruise control released" (1000) is
not attained:
- Check engine control module identification.
Repair Manual, Fuel Injection & Ignition, Repair Group 01
- If "G" is not displayed after component name, cruise control is not

activated. Activate cruise control system Page 01-209 .
01-208
Read Measuring Value Block 66 Display check, display field 4

0 km/h 1000 0km/h 0000
Test conditions Display field
4
Switch -B- in "OFF" (AUS) position 0000
Switch -B- to "ON" (EIN) position 0011
Memory set, switch -B- to "OFF" (AUS) before 0001
engaging
Button -A- pressed, "SET" (FIX) 0111
Switch -B- to "RES" (AUFN) 1011
If the nominal values in display field 4 are not attained even though switch
-B- is set to "ON" (0011):
- Connect VAG1598/31 breakout box to engine control module harness

Page 01-210 .
01-209
Activating cruise control
- Connect VAG1551 scan tool (VAG1552)

Page 01-241 .
- Insert "Address word 01" to select engine control

module.

Select function XX
- Press button -1- twice for "Login procedure" function 11 and press -Q-
Login procedure HELP Indicated on display

- Input code 11463 and press -Q- button to confirm input.
Deactivate cruise control
- Connect VAG1551 scan tool (VAG1552) Page 01-241 .

- Use "Address word 01" to select engine control module.

Select function XX
- Press button -1- twice for "Login procedure" function and press -Q-
Login procedure HELP Indicated on display

- Input code 16167 and press -Q- button to confirm input.
01-210
Testing wiring and components using

VAG1598/31 breakout box
Notes:
VAG1598/31 breakout box is designed to be

connected to the engine control module
harness and to the engine control module
simultaneously.
The effect of this design is that the electronic

engine controls remain fully functional while the
breakout box is connected (for e.g. measuring
signal strengths while the engine is running).
Look in the respective test descriptions to see if

it is necessary to connect the engine control
module to the breakout box.
Use multimeter (Fluke 83 or equivalent) or

VAG1715 Multimeter in addition to VAG1527B
voltage tester.
Always use test leads from VW1594 connector

test kit when connecting test equipment to
VAG1598/31 breakout box.
Once the engine control module has been

reconnected, adapt the engine control module
to the throttle valve control module.
Repair Manual, Fuel Injection & Ignition,

Repair Group 24
CAUTION!
Before connecting the test leads, switch the

test equipment to the appropriate measuring
range and observe the test requirements to
prevent damage to electronic components.
01-211
- Remove control module protective housing

cover.
- Using screwdriver, carefully pry off retainer (arrow).

- Release and disconnect harness connectors from control module.
- Connect VAG1598/31 breakout box to harness connector. Connect

breakout box Ground clip (not visible in illustration) to battery negative
terminal. Check respective test descriptions to see if it is necessary to
connect engine control module to breakout box.
- Perform tests as described in respective repair instructions.
01-212
- Disconnect 15-pin harness connector for cruise

control switch, clutch vacuum vent valve switch -
F36- and to brake vacuum vent valve switch -
F47- for cruise control.
- Check the following connections for a short to

positive, short to Ground (GND) or an open
circuit:
Gasoline engine: 2.7 liter/184 kW V6 twin-

turbo
Terminals on 15-pin VAG1598/31 breakout

harness connector box, socket
7 76
8 75
9 57
10 38
- If necessary, repair open or short circuit.
01-213
Terminals on 15-pin VAG1598/31

harness connector breakout box,
socket
13 39
to clutch vacuum vent valve

switch -F36- (terminal 1)
11 56
to brake vacuum vent valve

switch -F47- for cruise
control (terminal 2)
12 55
to brake vacuum vent valve

switch -F47- for cruise
control (terminal 4)
- If necessary, repair open or short circuit.
Differential, removing and installing Page 1 of 8
39-128
Differential, removing and

installing
Notes:
General repair notes page 00-27 .
Secure final drive to assembly stand page
39-123 .
Adjustments are required when replacing
components marked with 1) Adjustment
overview page 39-170 .
1 - Breather sleeve
With rubber valve
Installed position Item
2 - Final drive housing 1)
With drive pinion

Drive pinion, removing and installing
page 39-152
39-129
3 - Large tapered roller bearing outer race 1)
Driving out Fig. 7 , page 39-147

Pressing in Fig. 8 , page 39-148
4 - Adjustment shim "S1"
Note thickness
Adjustment overview page 39-170
5 - Cover for final drive 1)
With O-ring
Replacing O-ring
Insert O-ring with oil
6 - TORX bolt - 25 Nm
7 - Right gasket
Always replace page 39-113
8 - Socket head bolt - 25 Nm
39-130
9 - Right drive flange

Removing and installing Fig. 1
10 - Oil filler plug - 35 Nm
11 - Differential with ring gear 1)
Disassembling and assembling page 39-

136
12 - Oil drain plug - 35 Nm
13 - Socket
Holds the magnet in position
Press in until stop
14 - Magnet
15 - Small tapered roller bearing outer race 1)
Driving out Fig. 1 , page 39-144

Pressing in Fig. 2 , page 39-144
39-131
16 - Shim "S2"
Note thickness
List of adjustments page 39-170
17 - Left gasket
Always replace page 39-113
18 - Left drive flange
19 - Socket head bolt - 25 Nm
20 - Cover
Installing Fig. 2
39-132
Fig. 1 Removing and installing drive flange

- To loosen securing bolt, thread 2 bolts into drive flange and counter
hold using tire iron.
- Remove drive flange at installed bolts.
Fig. 2 Press in cover up to stop
39-133
Fig. 3 Installed position of breather sleeve
The breather sleeve must protrude 13 mm (measurement -a-) out of

housing after pressing in.
The slot in the rubber valve is parallel to direction of travel.
39-134
Differential, removing and installing
Rear final drive removed
VAG1306 drip tray
Removing
- Secure complete rear final drive to assembly stand page 39-123 .

- Place VAG1306 drip tray underneath and drain gear oil.
- Remove left and right drive flanges.

- To loosen securing bolt, thread 2 bolts into drive flange and counter
hold using tire iron.
- Mark left and right drive flanges.
- Remove drive flange at installed bolts.
- Remove mounting bolts for final drive cover.
- Remove final drive cover from axle housing and remove differential.
39-135
Installing
Installation is reverse of removal, noting the

following:
- Install differential.
- Replace O-ring for final drive cover and oil for

installation.
- Install final drive cover onto final drive housing

and tighten in diagonal pattern to 25 Nm.
- Replace drive flange seals page 39-113 .
- Fill gap between sealing lip and dust lip with

multi-purpose grease.
- Install drive flanges and tighten to 25 Nm.

- Top-up and check gear oil in rear final drive page 39-94 .
Description of work Page 1 of 111
10
Description of work
Engine oil level, checking
After turning engine OFF, wait approximately 3

minutes to allow oil to flow back into oil pan.
- Remove dipstick, wipe with a lint free cloth, and

re-insert fully.
Note:
Please observe waste disposal requirements!
- Remove dipstick and read oil level:
Marking ranges on dipstick.
CAUTION!
If oil level is above -a - there is risk of damage to Three Way

Catalytic Converter.
a - Oil level must be at top edge of shaded area but under no condition
above.
b - Oil may be topped off.
c - Oil must be topped off.
11
Engine oil, topping off
Specifications:
Temperature ranges
A = energy-conserving oil
B = multi-grade oil
Multi-grade oils specification API-SF or API-SG
12
Engine oil, oil filter; replacing
Notes:
Replace oil drain plug seal.
Use VAG 1307 or 1358 to extract engine oil. For

rapid extration of oil on V6 engines use probe
VAG 1358A/4.
Please observe waste disposal requirements!
Do not clean and re-use oil fiter!
Tightening torque of oil drain plug: 40 Nm (30 ft

lb).
Engine oil capacity (with filter change)
1.8 liter 5V turbo: 3.5 liter (3.7 qt)
2.7 liter V6 5V turbo: 6.0 liter (6.3 qt.)
2.8 liter V6 5V: 5.7 liter (6.0 qt.)
Procedure
- Loosen oil filter with tensioning strap (e.g. Hazet

2171-1 or equivalent) and remove.
- Clean sealing surface on engine.
- Lightly oil rubber seal.
- Thread on new filter and tighten by hand.
13
Engine and engine compartment - visual

inspection
WARNING!
Repair any defects found.
- Visually inspect engine and engine compartment

for leaks and damage.
- Visually inspect lines, hoses, and connections of

fuel system, brake system, and cooling and
heating system for leaks, worn areas, porosity,
and deterioration.
14
Cooling system antifreeze protection

and coolant level, checking
CAUTION!
Part numbers are for reference only. Always

check with your Parts Dept. for the latest
parts information.
Coolant antifreeze, Part No. G 11 prevents frost

and corrosion damage, lime deposits, and also
raises the boiling temperature. Cooling system
must be filled year round with antifreeze and
corrosion protection agent.
Concentration of coolant must not be reduced by

adding wa ter, even during summer or in warmer
climates. Coolant antifreeze percentage must be
at least 40%.
Because of its high boiling point, coolant

contributes to safe operation at high engine load,
especially in warmer climates.
- Check concentration of coolant antifreeze.
Antifreeze protection must be approximately

-25 C (-13 F) for US and -35 C (-31 F)
for Canada.
For antifreeze protection down to
approximately -40 C (-40 F), the

percentage of G 11 may be increased up to
60%. The percentage of G 11 must not
exceed 60%, higher amounts will decrease
frost protection and cooling capacity.
If antifreeze protection is not adequate, drain

off quantity indicated in following table and
top off with coolant antifreeze G 11.
15
Antifreeze protection
down to C ( F)
Amount
Actual value Desired
specification
0 (32 ) -25 (-13 ) 4.0
-35 (-31 ) 5.0
-5 (23 ) -25 (-13 ) 3.5
-35 (-31 ) 4.5
-10 (14 ) -25 (-13 ) 3.0
-35 (-31 ) 4.0
-15 (5 ) -25 (-13 ) 2.0
-35 (-31 ) 3.0
-20 (-4 ) -25 (-13 ) 1.5
-35 (-31 ) 2.0
-25 (-13 ) -35 (-31 ) 1.5

-30 (-22 ) -35 (-31 ) 1.0
0.5
-35 (-31 ) -40 (-40 )
- After road test, check coolant concentration.
- Check coolant level.
16
Delivery inspection:
At delivery inspection coolant level must be at

max. mark on expansion tank (engine cold).
Inspection service:
Coolant level between min. and max. markings.

With engine cold, coolant level must be between
min. and max. markings of reservoir; with engine
warm, level may be slightly above max. marking.
If coolant level is too low but antifreeze protection
is adequate, add required amount of mixture.
If coolant level is too low but antifreeze protection

adequate, add missing quantity according to
following mixing ratios:
Antifreeze Coolant Water

protection down to additive
-25 C (-13 F) approx. 40 % approx. 60
%
-35 C (-31 F) approx. 50 % approx. 50
%
-40 C (-40 F) approx. 50 % approx. 50
%
17
Dust and pollen filter element, replacing
- Remove right scuttle panel.
- Remove rain channel -A-.

- Remove filter element -B- from housing.
Notes:
Be sure dust and pollen filter housing gasket -C- is positioned correctly
and undamaged.
Rain channel -A- must be properly installed to prevent water from running
onto dust and pollen filter and into heating system.
- Install new filter element.

- Install gasket-C-, rain channel -A-, and right scuttle panel.
18
Noise insulation, removing and

installing
- Pull insulation pan to rear, off bumper cover and remove.
Note:
When installing noise insulation, be sure that it is inserted at front, over

bumper cover.
19
Diagnostic Trouble Code (DTC) Memory

interrogating, with VAG 1551 Scan Tool
Connecting Scan Tool (ST) VAG 1551- (up to

m.y. 1996)
- Move shift lever into position "P" or "N", and

apply parking brake (vehicles with Automatic
Transmissions).
- Open rear ashtray (center console) and remove Data Link Connector
(DLC) cover.
- With ignition turned OFF connect Scan Tool (ST) VAG 1551 to Data
Link Connector (DLC) with Adapter Harness VAG 1551/3.
20
Connecting Scan Tool (ST) VAG 1551- (from

m.y. 1997)
DLC is located below driver's knee bar to left

side of steering wheel
- Connect Scan Tool VAG 1551/1552 with diagnostic cable VAG 1551/3.
Continuation for all vehicles
- Start engine and run at Closed Throttle Position.

- Press brake pedal briefly once.
- Press print button to switch printer on (indicator lamp in button lights
up).
- Press key -1- for "Rapid Data Transfer" mode.
- Press key -O- twice to enter address word 00 for "Automatic Test
Sequence".
- Press -Q- key to confirm input.
VAG 1551 displays all known address words in sequence.
21
X DTCs recognized If control module answers with its identification the number of stored
Diagnostic Trouble Codes (DTCs) will be indicated or "No DTCs
Recognized" will be displayed.
If one or more DTCs are stored, all stored DTCs will be dis played and
printed out in sequence. Following this, VAG 1551 displays the next
address word.
VAG On Board Diagnostic HELP

- Automatic test sequence is ended once the readout shown here
1 - Rapid data transfer *) appears in the display.
2 - Blink code output *)
* Operating modes 1 and 2 are displayed alternately.
- Turn ignition OFE
Corrective action must be taken if DTCs are stored. Diagnostic report

should be attached to repair order.
Note:
For resetting service internal display and performing any emissions test
VAG 1551 must remain connected.
22
Spark plugs, replacing
- Remove engine cover.
Note:
To replace spark plugs, use Spark Plug Wrench 3122B.
- Install new spark plugs.

Tightening torque: 30 Nm (22 ft lb)
23
Plenum chamber and water drain valve,

checking for debris, cleaning if
necessary
- Check plenum chamber for signs of debris, e.g.

from leaves,clean If necessary.
- Check water drain valves for debris and proper

operation; clean or replace if necessary.
Note:
The water drain valves must not be blocked by

wax or undercoating, and must close properly.
Position of the water drain valves:
left - below brake servo unit
right - below battery
24
Lock carrier, moving into service position
Special tools
3369
1 - 45 Nm
2 - 45 Nm
3 - 10 Nm
4 - 10 Nm
5 - Hole
For tool 3369
6 - Hole in lock carrier
7 - Hole in fender panel
25
- Remove front bumper Repair Manual, Body

Exterior, Repair Group 63 .
- Undo 3 quick-release fasteners on noise
insulation at front.
- Remove air duct between lock carrier and air
cleaner (air duct is bolted to lock carrier).
- Remove retainer clips (if installed) for wiring
harness to left of radiator cowl.
- Remove bolt -2- on right and thread in special
tool 3369.
26
- Thread special tool 3369 into hole -5- (left).

- Remove bolts -1- and -3-.
- Remove bolts -4- and pull whole lock carrier out
as far as it will go.
- Secure lock carrier with suitable M6 bolts in hole
-6- (lock carrier) and hole -7- (fender panel).
- When lock carrier has been installed, check that
wiring next to radiator is correctly routed.
- Install front bumper Repair Manual, Body
Exterior, Repair Group 63 .
27
V-belt and ribbed belts, replacing (4-

cylinder engine AEB)
Lock carrier must be in service position Page

24
Removing
Vehicles with air conditioner
- Remove noise insulation Page 18 .
- Loosen securing bolts of tensioning roller for ribbed belt for A/C
compressor (arrows).
- Loosen ribbed belt and remove.
All models
- To loosen ribbed belt, turn tensioning element in direction of arrow.
28
Note:
The tensioning element for the ribbed belt can be locked in position by
inserting a suitable hex key (arrow) or mandrel 3204 into the securing
hole.
- Remove ribbed belt and release tensioning element.

- Secure belt pulley for viscous fan with an M5 x 60 bolt and unscrew
using an 8 mm hex key.
- Remove viscous fan.
29
- Remove V-belt pulley from coolant pump. Counterhold by inserting pin

(arrow) in pump pulley.
- Remove V-belt.
Installing
Installation is in the reverse order of removal. Also, note the following:
- Install V-belt on pulleys and assemble two sections of pulley on coolant

pump without tightening bolts.
- Tighten bolts securing two sections of pulley in stages while turning
coolant pump.
As bolts are tightened, V-belt should gradually move outward until
seated on running surface.
- Tighten bolts to 25 Nm.
30
Note:
It is not possible to adjust the tension of the V-

belt for the coolant pump.
- Tighten viscous fan mounting to 45 Nm.
- Install ribbed belt over crankshaft pulley, viscous

fan pulley and power steering pump pulley. If
necessary, pull belt upward using a suitable tool.
- Turn ribbed belt tensioning element in direction of arrow.

- Install ribbed belt over Generator pulley last. Release tensioning
element.
- Check that ribbed belt is properly seated.
Routing of ribbed belt Page 32
Vehicles with air conditioner
- Install ribbed belt for A/C compressor.

Routing of ribbed belt Page 32
- Apply torque wrench to hex on tensioning roller and tension with a
torque of 25 Nm
- Tighten bolts -A- to 20 Nm
31
All models
- Start engine and check belt running.
- Check again to ensure that bolts for coolant

pump pulley are tightened to correct torque.
32
Routing of V-belt and ribbed belts
1 - Tensioning element for ribbed belt

2 - Generator
3 - Viscous coupling
4 - Coolant pump
5 - Power steering pump
6 - V-belt
For coolant pump
7 - Ribbed belt
For Generator, power steering pump and
viscous fan
8 - Vibration damper
33
9 - Tensioning element for ribbed belt

For A/C compressor
10 - Ribbed belt
For A/C compressor
11 - A/C compressor
34
Poly-ribbed belt, checking, removing,

and replacing
Check condition of Poly-ribbed belt for:
Splits in base material (cracks, core

fractures, cross section fractures).
Separation of layers (top layer, tensile

cords).
Bursting on base material.
Fraying of cords.
Flank wear (material flaking, frayed flanks,

hardening of flanks (glassy surface), and
surface cracks).
Traces of oil and grease.
Note:
If defects exist, replace Poly-ribbed belt.
Poly-ribbed belt replacement interval
- Every 144,000 km (90,000 mi.)
Removing
- Move body, front, to engine service position

Page 24 .
- Remove ribbed V-belt cover.
35
The Poly-ribbed belt is removed by rotating tensioner in a clockwise

direction with a 17mm wrench or socket. Hold tensioner in place during
belt removal with Drift 3204.
- Remove Poly-ribbed belt.
Note:
When removing it is important to mark the running direction of belt.

Changing the belt running direction could lead to excess wear.
Installing
- Install Poly-ribbed belt over drive pulley, guide pulley, and tensioning
pulley in that order.
- Remove Drift 3204.
- Install ribbed V-belt cover.
Routing of Poly-ribbed belt -D2-.
36
Manual transmission/final drive oil level,

checking
5-speed manual transmission 012/01W
Key 3357, or
Hex key socket attachment, 17 mm AF
Note:
The vehicle must be absolutely horizontal when

checking transmission oil level. This work is
best performed over an inspection pit or using a
four column lifting platform.
The prescribed oil level is to be adhered to

exactly; the transmission reacts very sensitively
to over-filling.
The oil filter plug is on the left of the

transmission below the speedometer sender; it
may be concealed by the heat shield for the
drive shaft.
Depending on the version installed, use either special tool 3357 or a

17 mm hex socket key to loosen the oil filter plug.
37
- To check oil level, unscrew oil filler plug (arrow).

- Check oil level with locally manufactured tool, e.g. a piece of angled
wire.
Specification: oil level 7 mm below bottom edge of oil filler hole
CAUTION!
If the oil level is below the specified area, check the transmission for
leaks. It is not sufficient to top up with oil.
- If transmission has no leaks, top up with gear oil: SAE 75 W 90

(synthetic oil), part number G 052 145 S2 (1 liter).
CAUTION!
Part numbers are for reference only. Always check with your Parts
Dept. for the latest parts information.
- Install oil filler plug.

- Tighten oil filler plug to 25 Nm.
38
6-spd. manual transmission 01E all wheel

drive
Note:
For checking oil level the vehicle must be

stationary and on a level surface (e.g engine
off, standing on an alignment lift).
The oil level must be kept at the specified level.

The transmission may be damaged by over-
filling.
- Remove filler plug -B-, on differential cover, in front of drive axle flange.
- Check oil level using tool such as angled wire.
Specification: level 1 mm below bottom of oil filler hole.
CAUTION!
If the oil level is too low, the transmission must be checked for leaks
and repaired. It is not sufficient to just top off oil.
- If there are no leaks, top up with gear oil: SAE 75 W 90 (synthetic oil),
part number G 052 145 S2 (1 liter).
CAUTION!
Part numbers are for reference only. Always check with your Parts
Dept. for the latest parts information.
- Tighten oil filler plug to 40 Nm.
39
Automatic Transmission Fluid (ATF),

checking (01V transmission)
Requirements for check:
Vehicle standing on level surface.
Transmission must not be in fail-safe mode.
Shift lever in "P" position, parking brake

applied.
Engine idling.
Air Conditioner and heater OFF.
ATF temperature must not exceed 40 C

(104 F) at start of test.
CAUTION!
Part numbers are for reference only. Always

check with your Parts Dept. for the latest
parts information.
Notes:
Only ATF with designation ESSO LT 71 141
may be used. Do not use any lubricant

additives.
Automatic transmission fluid: ATF, part

number G052 162 A2 (1 liter)
An ATF level check when transmission oil

temperature is too low results in overfilling;
when too high results in underfilling.
40
CAUTION!
Too much or too liffle ATF will affect the

operation of the transmission. The ATF level
must be checked at regular intervals.
The oil level is correct if only a slight amount of oil runs out when ATF
temperature is between 30 C (86 F) and 45 C1) (113 F) (caused by
increase of oil level when heated).
WARNING!
Wear protective glasses.
- Hang filled ATF reservoir VAG 1924 as high as possible (example:

radiator grill).
- Shift lever in "P", engine running at idle.
- Place oil drip pan under transmission oil pan.
The ATF temperature is measured temperature using the VAG 1551 Scan
Tool.
- Connect VAG 1551 as described on Page 19 .

- Press key -1- for " Rapid Data Transfer " mode.
1) For warmer climates, 50 C (122 F).
41
- Press keys -0- and -2- to select address code -

02- "Transmission Electronics", and confirm with
key -Q-.
- Press key to advance program.

08- "Read Measuring Value Block' and confirm
with key -Q-.

04- "Display Group Number", and confirm with
key -Q-.
Read measuring value block 1

- Display shows ATF temperature (in C) appears in measuring value
1234
block 1.
- Remove ATF filler plug -2-.

- With ATF temperature between 30 C (86 F) and 45 C1) (113 F1)) a
slight amount of fluid will flow from filler hole when ATF level is correct.
- If necessary drain or top off ATF to attain correct fluid level.
- Top off ATF with filler hook from VAG 1924 ATF reservoir.
- Insert VAG 1924 ATF reservoir filler hook into filler hole and top off until
a slight amount of fluid flows from filler hole.
1) For warmer climates, 50 C (122 F).
42
Note:
Fit filler hook into one of the oil deflector cap -4-
slots placed on the filler opening.
CAUTION!
Do not press filler hook upward or oil

deflector cap can be pushed off.
- Reinstall ATF filler plug -2-.
Tightening torque: 80 Nm (59 ft lb).

06- "Data Transmission Ended" and confirm with
key -Q-.
43
Final drive oil level, checking
Automatic transmission 01V all wheel drive
- Remove oil filler plug -arrow- and check level.

Specification: oil level must be at bottom of filler hole.
CAUTION!
If the oil level is too low, the transmission must be checked for leaks
and be repaired. It is not sufficient to just top off oil.
- If there are no leaks, fill to correct level using gear oil: SAE 75 W 90
(synthetic oil), part number G 052 145 S2 (1 liter)
- Replace sealing ring on plug.
- Install plug and tighten to 30 Nm.
44
Power steering fluid level, checking
Requirements:
Engine at normal operating temperature.
Vehicle stationary.
Front wheels in straight ahead position.
- Remove cap with dipstick from expansion tank

and wipe off dipstick with a lint-free cloth.
- Reinstall cap with dipstick and remove again.

- Read max. and min. markings on dipstick. top off with G 002 000
hydraulic oil, if necessary, as follows:
Fluid level must be at max. marking when inspection is performed.
Inspection service:
Fluid level between min. and max. markings.
Note:
If oil level has dropped to the min. marking, check power steering system,
including hoses, and lines. It is not enough simply to top off the hydraulic
oil.
45
Tie rod ends, checking
Requirements:
Vehicle raised, wheels off the ground.
- Check play by moving tie rods and wheels.
Specification: no play.
- Check attachment.
- Check dust boots for damage and correct

installation.
46
Tires, checking
- Check treads and side walls for signs of

damage, if necessary, remove any foreign
bodies, such as nails and glass splinters.
- Check that tires are the same type and tread

pattern.
Inspection service:
- Measure tread depth.
Minimum tread depth: 1.6 mm (0.0625 in.)
If tread depth is close to legal permissible

minimum, i.e. if the 1.6 mm high wear indicator
spaced around tire circumference no longer has
any tread pattern, the customer must be in
formed.
Tires should also be checked for scuffing, wear

on one side, porous side walls, cuts, and
fractures.
Any defects found must be reported to the

customer.
WARNING!
For safety reasons, only tires of same type

and tread pattern should be installed on all
four wheels.
47
CAUTION!
Tires of same type and tread pattern must be

used on cars with All Wheel Drive (otherwise
risk of damage to central differential).
- Check tread wear pattern:
Tread wear pattern on front tires is an indication

of whether toe and camber settings need to be
checked:
"Feathering" on tread indicates incorrect toe.
If tread is worn on one side, this is usually

caused by incorrect camber.
If wear of this nature is noticed, check wheel

alignment.
48
Tire inflation pressure, checking, and

correcting (including spare wheel)
The correct inflation pressures for summer tires are listed on the sticker
on the inside of the fuel tank filler flap.
Note:
The pressures listed on the sticker apply to cold tires. When the tires
are warm the actual pressures will be higher but must not be reduced.
When using winter tires, pressures should be increased by 3 psi.
Spare wheel
Spare wheel with standard-size tire.

Inflate to the maximum pressure specified for the vehicle.
Temporary (compact) spare wheel
The correct inflation pressure is indicated on the tire side wall.
Note:
It is important to install dust caps on the tire valves. Otherwise, dirt
can obstruct the valve pin and cause loss of air.
On vehicles with steel rims and full-diameter wheel covers, check the
valve extensions for dirt and damage which could cause leaks.
Replace if necessary.
49
Wheel bolts, tightening to specified

torque
Trim cap
Puller -A- for removing the trim cap is in the vehicle tool kit.
Wheel bolts
The adapter for loosening and tightening the anti-theft wheel bolts is in the
vehicle tool kit.
Note:
Ensure that the wheel bolts are tightened diagonally and alternately to the
following tightening torque:
- After completing work, replace adapter in vehicle tool kit.
Correct installation of wheels
When installing the wheels, note the following points to ensure that the
wheels remain secure at all times:
Always tighten the wheel bolts to the specified torque; excessive

torque can distort the wheel bolt seats in the rim.
50
When installing a wheel, do not torque down

the first wheel bolt immediately (for instance,
with an impact wrench). This would prevent the
other bolts from centering the wheel properly
when they are threaded in; the rim could then
come loose, even though the bolts have been
tightened to the specified torque.
Before installing the wheels, examine the seats

of the wheel bolts and the contact surfaces
between the rims and the hubs for rust and
corrosion. Clean off these parts if necesary,
otherwise this can affect the clamping force of
the bolts after installation, and the rims can
come loose.
WARNING!
If the points listed above are not observed,

the wheel mountings can come loose and the
wheel bolt seats can become distorted.
This distortion may be very slight and not

visible to the naked eye.
Even this slight distortion of the wheel bolt

seats can prevent the rims from being held
firmly and the wheels will come loose
repeatedly.
51
Brake pad thickness, checking
Inspection service:
Dimension -a- = pad thickness including backing plate. Wear limit = 7 mm

(0.28 in.).
Thoroughly remove all dirt from wheels.
- Determine thickness of outer and inner pads by inspecting visually.

View through opening in wheel.
Use a flashlight and mirror if necessary.
If pad thickness including backing plate is 7 mm (0.28 in.) or less the

brake pads have reached or exceeded wear limit and must be replaced.
- Tighten wheel bolts to 110 Nm (81 ft lb).
52
Brake system - visual inspection
WARNING!
Any defects found must be repaired.
- Inspect brake master cylinder, vacuum brake

booster, hydraulic unit, brake pressure regulator,
and brake calipers for leaks and damage.
- Brake hoses must not be twisted.
- Brake hoses must not make contact with any

part of vehicle when steering is at full lock.
- Inspect brake hoses for porosity and

deterioration, brake hoses and brake lines for
chafing.
- Inspect the brake connections and attachments

for correct seating, leaks and corrosion.
53
Brake fluid level, checking
WARNING!
Use only new brake fluid confomning to US

Standard FMVSS 116 DOT 4. Genuine VW,
Audi brake fluid conforms to this
specification.
Brake fluid is poisonous. Do not ingest brake

fluid. Wash thoroughly with soap and water if
brake fluid comes into contact with the skin.
CAUTION!
Do not let brake fluid come into contact with

paint because of its caustic effect
Brake fluid absorbs moisture from

surrounding air and should always be stored
in airtight containers.
Brake fluid level must be at max. marking at time

of delivery.
Note:
To avoid brake fluid over flowing do not exceed

the max. marking.
54
Inspection service:
- Always consider brake pad wear when checking

brake fluid level. When driving, a slight drop in
brake fluid level results from normal wear and
automatic adjustment of brake pads.
- If brake fluid level is at minimum marking or

slightly above, brake pads are close to wear
limit, it is not necessary to add fluid.
- If brake pads are new or well away from wear

limit, brake fluid level must be between min. and
max. markings.
- If brake fluid level has dropped below min.

marking, check brake system before adding
brake fluid.
55
Brake fluid, changing
WARNING!
Use only new brake fluid conforming to US

Standard FMVSS 116 DOT 4. Genuine VW,
Audi brake fluid conforms to this
specification.
Brake fluid is poisonous. Do not ingest brake

fluid. Wash thoroughly with soap and water if
brake fluid comes into contact with the skin.
CAUTION!
Do not let brake fluid come into contact with

paint because of its caustic effect
Brake fluid absorbs moisture from

surrounding air and should a/ways be stored
in airtight containers.
Do not allow brake fluid to come into contact

with fluids containing mineral oils or
gasoline cleaning products.
Mineral oils damage plugs and seals of the

brake system.
56
- Connect Brake Bleeder US 1116 to brake fluid reservoir. Use adapter -

1-, plastic fitting VAG 1238 B/2, seal -3-, and connector -4-.
- Use a suction bottle to draw off as much brake fluid as possible.
CAUTION!
Do not use cleaning cloths that have been contaminated by

mineral oils for cleaning brake filling and bleeder fittings.
Do not re-use extracted brake fluid.
- Install and adjust brake pedal depressor between driver's seat and
brake pedal.
- Open bleeder fittings and pump in fresh fluid forcing out appropriate
amount of used brake fluid.
Note:
Please observe waste disposal requirements.
57
Sequence: Brake fluid quantity which
Brake calipers must flow out of brake
calipers:
rear right approx. 0.3 liters (0.32 qt)
rear left approx. 0.3 liters (0.32 qt)
front right approx. 0.2 liters (0.21 qt)
front left approx. 0.2 liters (0.21 qt)
Total quantity: 1 liter (1.06 qt)
- Disconnect Brake Bleeder US 1116 from brake

fluid reservoir and remove brake pedal
depressor.
- Check pedal pressure and free travel at brake

pedal.
Max. free travel: 1/3 of pedal travel.
58
Transport locks, removing
On certain vehicle versions, blocking elements -

1- (in a luminous color) are installed in the front
suspension struts. These models are
recognizable by a tag on the mirror.
- Relieve pressure on coil spring (e.g. vehicle on

lift).
Note:
It is not necessary to remove wheels.
- Pull auxiliary spring -2- down.

- Remove 2 blocking eiements -1- fitted to each suspension strut.
59
Undercoating - visual inspection for

damage
When performing visual inspection, pay attention

to underbody, wheel wells, and rocker panels.
Any damage or defects found must be repaired.
60
Lock cylinders, lubricating
- Lubricate with lock cylinder lubricant spray G

000 400 01.
61
Door check straps, lubricating
- Lubricate front and rear door check straps only at points indicated -
arrows-.
- Lubricate with lubticating paste G 000 150.
62
Door locks, locking buttons, child safety

lock - checking operation
WARNING!
Remove, clean, and grease all door locks

which do not operate freely.
Door locks and locking buttons:
- Open and close driver and front passenger door.

Check whether locking buttons move up and
down, respectively, when this is done.
- Press locking button on front passenger door

and rear doors down, close doors. Doors must
be locked.
It must not be possible to press down locking

button on driver door so long as door is open.
Child safety lock (rear doors):
- Move lever on door lock down in direction of

arrow (see marking on door lock). Door lever on
inside must be blocked and locking button must
be pulled up.
63
Power window regulators - checking

positioning
Power window regulator can lose position

memory if battery is disconnected.
- Press switch to raise window fully.
- Again press switch to raise window for an

additional 1 second.
- Press switch to lower window. Side window must

automatically open to full extent.
64
Battery electrolyte level, checking,

refilling if necessary
Battery is located in plenum chamber.
- Check electrolyte level:
Electrolyte level must be between the min.

and max. markings.
- Refill battery cells to max. marking with distilled

water, if necessary.
65
Battery no-load voltage, testing
Requirements:
Vehicle must have been standing for at least

two hours in the no-load state prior to
measurement (no engine starts, no charging
and discharging).
Ignition turned OFF
- Measure voltage with digital multimeter (Fluke

83, or equivalent) between poles of installed
battery.
If instrument indicates 12.5 volts or higher,

battery is OK.
If voltage is below 12.5 volts, determine cause

and repair or replace as necessary.
66
Windshield washer nozzles, adjusting
Check setting of nozzles, adjust if necessary with

windshield washer aiming tool 3125A.
CAUTION!
To avoid damage never use a needle or

similar device to adjust nozzles.
Nozzle setting for windshield:
a = 235 mm (9.25 in.) c = 80 mm (3.15 in.)
b - 445 mm (17.52 in.) d = 620 mm (24.41 in.)
Note:
If spray is uneven or cannot be set to specified dimensions replace spray

nozzles.
- Fill windshield washer reservoir.

- Always add windshield cleaner to water in reservoir (antifreeze in
winter).
67
Headlights, adjusting
Requirements
Tires inflated to correct pressure.
Lenses clean and in proper condition.
Reflectors in proper condition.
Springs settled (load vehicle with approx. 75

kg (165 Ibs) on driver's seat and roll several
meters (yards).
Vehicle standing on level ground.
Adjust headlight housing from top with

screwdriver or allen wrench.
Illustration shows adjusting screws for right headlight. Adjusting screws for
left headlight are symmetrically opposite.
A = Vertical adjustment
B = Lateral adjustment
68
Headlights, aiming using Hella Universal

Beamsetter IV
Service
Align vehicle headlamps using the VAS 5107

(Hella Universal Beamsetter IV) and the following
procedure:
Additional instructions and diagrams

Instruction Manual for the Hella Beamsetter
Series IV
- Position vehicle on a flat floor surface that meets the following (ISO
10640) specifications:
0.5mm or less slant from front wheel to back wheel of the
Beamsetter -A-.
1mm or less slant per meter for the length of the vehicle -B-.
- Clean headlight lenses.
- Adjust vehicle tire pressure to specifications.
Have a second technician sit in the driver's seat while aligning the
headlights.
- Bounce front and rear of vehicle up and down several times to settle
vehicle suspension.
69
Setting low beam alignment of driver's side

headlight
- Move Beamsetter into position in front of the

vehicle so it is aligned with the vehicle and
Beamsetter box is 30 to 70cm (12 to 28 in.) from
the driver's side headlight.
- Switch headlights ON in low beam position.
- Align Beamsetter box so it is centered on the

headlight (align vertically then horizontally).
Note:
Use the arrows on the Beamsetter box as a

guide.
You may want to use a straight edge or tape

measure, because alignment must be within
3cm (1.2 in.) of the center of the headlight.
- Without moving the Beamsetter, slide Broad-

band sight toward center of vehicle (Broad-band
sight can also be moved up and down for a
better position).
Use Broad-band sight to make final alignment of

Beamsetter box to vehicle by:
- Loosening hand-wheel that locks column in

place.
- Sighting down through the slit in the Broad-band

sight and rotating Beamsetter box and column
until two similar points on vehicle are aligned.
70
Note:
Try using corners of the headlight housings or

two screws that are the same height and as far
apart as possible on the vehicle.
- Carefully tighten hand wheel without changing

Beamsetter position.
- Find correct State or Province Inclination %

specification for the low beam adjustment (If
there is no local specification use 1.2%).
Note:
DO NOT use the Inclination % molded into the

plastic of the headlight housing near the
headlight adjustment screws; it is for Europe
only!
- Set Beamsetter "Scaled wheel" to the proper low

beam inclination %.
- Adjust height (vertical) alignment first. Turn

headlight height adjuster screw to align the
upper edge of the flat portion of the beam with
the center horizontal line of the grid on the
Beamsetter pattern screen.
71
Note:
VOL is the correct beam pattern for both right

and left headlights.
- Adjust lateral (horizontal) alignment of driver's side headlight so that

the peak (highest point) of the headlight beam pattern aligns with the
right edge of the target box of the grid on the pattern screen (it should
match the VOL pattern shown on the Beamsetter box).
Note:
If the height alignment changed, readjust.
Checking driver's side headlight high beam alignment
- Switch headlights ON in high beam position.

- Realign Beamsetter box with the high beam headlight if necessary.
- Set Beamsetter "Scaled wheel" to 0%.

- Cover low beam lamp (use hand or small piece of cardboard) and
check that the "hot spot" of high beam pattern is centered on the
square target box of the pattern screen.
72
Note:
High beam pattern is built into the reflector

design and cannot be adjusted separately.
If high beam pattern is way out of adjustment:
- Inspect for reflector damage.
- Replace reflector if needed.
Note:
Always align headlight in the low beam position.
Aligning fog lamp
- Switch fog lamps ON.
- Align Beamsetter box with fog lamp (make sure

it is between 30 and 70cm from the fog lamp
lens).
- Set Beamsetter scaled wheel to 1.4%.
Adjust fog lamp so the top of the beam pattern aligns with the centerline
of the target grid on the beam pattern screen.
73
Passenger's side headlight, alignment
- Move Beamsetter to the passenger side of the

vehicle and follow the same procedures to align
the Beamsetter box to the headlamp.
- Align headlight low beam, check high beam and

align fog lamp.
Note:
Make sure to reset the Beamsetter "Scaled

wheel" to the proper setting each time you
change from low beam to high beam or to fog
lamp.
- Ensure that headlights and vehicle body are

clean and free of fingerprints.
74
Headlight cleaning system nozzles,

adjusting
Check setting of nozzles, adjust if necessary with

Windshield Washer Aiming Tool 3125A.
CAUTION!
To avoid damage never use a needle or

similar device to adjust nozzles.
Nozzle setting:
a = 65 mm (2.56 in.) c = 40 mm (1.57 in.)
b = 50 mm (1.97 in.) d = 90 mm (3.54 in.)
75
Wiper blades, adjusting parked position
Check wiper blades and arms for signs of

damage, replace if necessary.
Parked position:
Windshield:
- Position wiper blades on markings -A- in windshield and tlghten.

- Operate single wipe control.
- Align wiper arms and tighten.
Tightening torque of wiper arms: 16 Nm (12 ft lb).
76
Wiper blade contact angle, adjusting
Note:
Possible causes of wiper blade chatter:
Scratched windshield
Rubber part of wiper blade is out of the frame or

torn
Windshield wiper arms/blades are loose or

bent
Wiper blades are waxy or buckled
If none of these causes apply to the problem,

then the angle of the wiper arms to the
windshield must be checked and if necessary
adjusted before replacing the wiper blades.
Special tools test equipment and auxiliary

items
3358 B Windshield wiper adjuster.
77
Checking wiper arm angle
- Bring wiper arms into park position.
- Remove wiper blade.
- Insert wiper arm -2- into 3358 B windshield wiper adjuster and lock in
place with stop screw -3-.
- Compare displayed angle with specified value.
Specified values for angle of wiper arm to windshield
Driver's side -3
Passenger side -3
Tolerance 0
78
Adjusting wiper arms
- Bring wiper arms into park position.
- Remove wiper blade.
- Place wiper arm -2- in 3358 B windshield wiper adjuster and lock in
place with stop screw -3-.
- Place 24 mm open end wrench -1- onto adjusting device as shown and
set wiper arm -2- to specified value (arrow)
Specified values Page 77 .
- Loosen stop screw -3- and remove wiper arm -2- from adjusting device.
- Again place wiper arm -2- into windshield wiper adjuster and again lock
in place with stop screw -3-.
- Compare displayed angle with specified value.
Specified values Page 77 .
- If necessary, repeat setting and checking procedure until specified
value is attained.
- Remove adjusting device and install wiper blade.
79
Radio anti-theft coding, activating
See Radio Owner's Manual.
80
Service Reminder Indicator (SRI),

resetting
Vehicles up to model year 1997
If service date has been reached, service event

which is due appears as a flashing display after
ignition is turned ON. Flashing continues for a
few seconds after engine is started.
The following displays are possible:
OIL Engine oil change

In 1 Inspection service
In 2 Inspection service with additional work
A service event which is due is already displayed

1000 km (620 mi.) or 10 days before.
Service Reminder Indicator (SRI) must be

matched during Delivery Inspection or during
each Inspection Service to the km and time
specifications until next service event with help of
Scan Tool (ST) VAG 1551.
- Select adaptation channels individually and

enter relevant specified values.
81
Service Adaptation Specification Entry

Type channel
OIL 05 12000 km 00012
In 1 06 24000 km 00024
(distance)
In 1 (time) 07 365 days 00036
In 2 08 730 days 00073
82
The following service types should be adapted

depending on the inspections performed.
Inspection Service type to Adaptation

be adapted channel
performed
Delivery OIL 05
Inspection
In 1 (distance) 06
In 1 (time) 07
In 2 08
OIL OIL 05
In 1 OIL 05
In 1 (distance) 06
In 1 (time) 07
In 2 OIL 05
In 1 (distance) 06
In 1 (time) 07
in 2 08
83
Scan Tool (ST) VAG 1551 Connecting
- Move shift lever into position "P" or "N" and

apply parking brake (vehicles with Automatic
Transmissions).
- Open rear ashtray (center console) and remove Data Link Connector
(DLC) cover.
- With ignition turned OFF connect Scan Tool (ST) VAG 1551 to DLC
with Adapter Harness VAG 1551/3.
Service Reminder Indicator (SRI) Programming
- Turn ignition ON.

- Press key -1- for "Rapid Data Transfer" mode.
- Press keys -1- and -7- for address word "Dash Panel Insert"; confirm
with key -Q-.
- Advance program with key.
- Press keys -1- and -0- for "Adaptation" function; confirm with key -Q-.
84
Channel 05 Service Reminder Indicator (SRI)

display for OIL
- Press keys-0-and-5-for "Adaptation Channel 05";

confirm with key-Q-.
- Display shows kilometers remaining until OIL service (in this case
<-13-> 00001, indicating 1,000 km remaining).
Channel 5 Adaptation 1 Q
Appears in display.
Enter Adaptation value XXXXX
- Enter 00012 for 12,000 km until next oil change; confirm with key -Q-
The figure can be entered in increments of 1000 km.
- Newly entered figure appears in display; confirm with key -Q-.
<-13->
- Confirm with key -Q-.

- Adaptation of Channel 05 is ended.
Select function XX
85
Channel 06 Service Reminder Indicator (SRI)

Display for Inspection 1
- Press keys -0- and -6- for "Adaptation Channel

06"; confirm with keys -Q-.
- Display shows kilometers remaining until Inspection -1- (in this case
<-13-> 00001, indicating 1,000 km remaining).
Appears in display.
- Enter 00024 for 24,000 km until next inspection 1; confirm with key -Q-.
The figure can be entered in increments of 1000 km.
<-13->

Select function XX
86
Channel 07 Service time until Inspection 1

07"; confirm with key -Q-.
- Display shows time remaining in days until Inspection -1- (in this case
<-13-> 00001, indicating 10 days remaining).
Appears in display.
- Enter 00036 for 365 days until next inspection 1; confirm with key -Q-.
The figure can be entered in increments of 10 days.
<-13->

Select function XX
87
Channel 08 Service time until Inspection 2

08"; confirm with key -Q-.
- Display shows time remaining in days until Inspection 2 (in this case
<-13-> 00037, indicating 370 days remaining).
Appears in display.
- Enter 00073 for 730 days until next inspection 1; confirm with key -Q-.
The figure can be entered in increments of 10 days.
<-13->

Select function XX
88
Resetting service interval display
Vehicles from model year 1998
The service interval display must be reset as part

of the Pre-Delivery Inspection and also after
every Oil Change Service and Inspection
Service.
Delivery inspection
The service interval display can be reset using

one of two methods:
Using the adjustment buttons for the trip

recorder and clock on the instrument cluster
- Reset "service OIL" and "service INSP" Page

92
or
Using VAG 1551 Scan Tool
- Select adaptation channel 02 and enter

adaptation value "00000" Page 89
89
Oil Change Service and Inspection Service
When a service is due, the type of service

required will be indicated by a flashing message
on the trip recorder display when the ignition is
switched on. The message will continue to flash
for up to 60 seconds after the engine has been
started.
Display Type of service due

service OEL Oil Change Service
service INSP Inspection Service
When a service is due, this will be indicated

either 1,000 km or 10 days in advance.
Resetting service interval display with VAG

1551
- Connect VAG 1551 Page 83 .
VAG On Board Diagnostic HELP Indicated in display (1) appears alternately)

1 - Rapid data transfer1)
2 - Blink code output1) - Enter "1" to select "Rapid data transfer".
90

Select function XX
- Enter "17" to select address word "Instrument cluster" and confirm
entry with Q key.
8D0919860G B5 Instr cluster VDO D09 Indicated on display (example)

- Press key twice.
- Enter "10" to select the function "Adaptation" and confirm entry with Q
key.
Adaptation
Feed in channel number XX
- Enter "02" to select adaptation channel 02 and confirm entry with Q
key.

- - - The type of service will be indicated (example: 11)
0 - means no service is due
1 - means that an Oil Change Service is due
10 - means that an Inspection Service is due
11 - means that both and Oil Change Service and an Inspection
Service are due
- Press key.
91
Enter adaptation value XXXXX
- Enter appropriate adaptation value for type of service which has been
performed. The values are as follows:
Adaptation value Type of service cancelled

00000 Delivery inspection
00000 service OIL and service INSP
00010 service OIL
00001 service INSP
Example:
- Enter "00000".
Enter adaptation value 00000
- Confirm entry with Q key.
- - -
- Press key to terminate resetting of service interval display.
92
Resetting service interval display with

adjustment buttons for trip recorder and
clock.
- Press trip recorder reset button -2- on instrument cluster and at same
time switch ignition on.
The trip recorder display -3- will read "service OIL".
- Release button.
- Pull clock adjuster button -1- on instrument cluster and hold for approx.
2 seconds. This resets "service OIL" display.
Note:
Depending on the make of the instrument cluster, the display on the trip
recorder will either continue to read "service OIL" (Nippon Seiki) or
change to "- - -" (VDO).
- Press trip recorder reset button -2- again to advance to next type of
service.
- Release button.
The trip recorder display -3- will read "service INSP".
93
- Pull clock adjuster button -1- on instrument cluster and hold for approx.
2 seconds. This resets "service INSP" display.
Note:
Depending on the make of the instrument cluster, the display on the trip
recorder will either continue to read "service INSP" (Nippon Seiki) or
change to "- - -" (VDO).
94
Clock, setting
Clock is included in tachometer display. To set

time, pull out instrument panel light dimmer
switch.
When switch is pulled out briefly, hands will

advance a minute at a time. Pulled out and held,
hands will advance slowly at first, then rapidly.
95
RAPGARD , inspection, removal and

disposal
From my 2002
Service
Within 48 Hours after arrival at Dealer:
Inspection
- Inspect RAPGARD for damage or peeling.
If RAPGARD is disturbed (dented, scratched,

etc.):
- You must note the damage on the Carrier

Delivery Receipt, including damage type, extent
and location. Failure to note damage on the
Carrier Delivery Receipt will result in non-
payment of the repair.
Note:
RAPGARD must be removed from the

vehicle no later than six months after
application. See sticker (location on vehicle
body varies) for detailed information.
96
Within 72 Hours prior to delivery to the

Customer:
Remove RAPGARD from vehicle.
Wash vehicle exterior.
Inspect paint surfaces, moldings and glass.
Protect the paint surface of all new vehicles

by applying 3M Perfect-It Paste Wax
(3M Part No. 39526) or equivalent.
Removal
Vehicle must be at room temperature.
The ideal body surface temperature for

RAPGARD removal is 60 F (15.5 C) to 80
F (26.6 C).
If body surface temperatures are below 60 F

(15.5 C) or above 80 F (26.6 C) then:
Removal procedure should be performed

indoors after surface temperatures have
been allowed to stabilize within the given
range.
- Rinse vehicle thoroughly with water to remove

surface dirt or dust and to help stabilize body
surface temperatures.
- Starting at the corners of each panel, carefully

remove RAPGARD from vehicle.
97
RAPGARD , paint inspection after removal
- Inspect painted surfaces under one of the

following lighting conditions:
Indoors under fluorescent lighting.
Outdoors under bright sunlight.
Important!:
If any defects on the exterior have been identified

(scratches, dings, dents and other types of body
damage):
- Contact your Service Manager and arrange to

repair defects immediately.
Note:
After removal of RAPGARD , some vehicles

may exhibit temporary paint discoloration or paint
swelling (caused by trapped moisture under the
RAPGARD ).
This temporary swelling is caused by the paint

finish absorbing moisture trapped under the
RAPGARD film.
This swelling will disappear with exposure to

the sun or heat lamps within 2 - 3 hours. Severe
Paint swelling may require 2 - 3 days to
recover.
DO NOT buff or refinish paint for this condition!
98
Adhesive residue removal
CAUTION!
Always read and follow manufacturer

Cautions and Warnings regarding use of
product.
If RAPGARD adhesive residue remains on

paint finish, remove with a non-abrasive polishing
product such as, (3M Part No. 5995) light colors
or (3M Part No. 5996) dark colors.
Thick lines of adhesive residue can be removed

with general purpose adhesive cleaner (3M Part
No. 08987-aerosol, or Part No, 08984-qt. can) or
equivalent.
Note:
Paint discoloration (looks like shaded or dark

magic marker lines) can be removed with a heat
gun using the following procedure:
- Hold heat gun approximately 3 in. away from

affected paint surfaces and apply heat using
slow oscillating motions until discoloration is
gone.
- If discoloration remains, wipe the heated area

with Isopropyl alcohol and repeat procedure to
increase surface drying.
99
Important!
After inspecting and removing RAPGARD ,

washing vehicle, inspecting and repairing any
defects in paint surfaces, moldings and glass:
- Protect the vehicle paint surface by applying 3M

Perfect-It Paste Wax (3M Part No. 39526) or
equivalent.
RAPGARD Disposal
RAPGARD can be disposed as normal paper

waste. If unsure about proper disposal
procedures in your area, check local regulations.
100
Transportation wiper blades, removing

at vehicle delivery
From my 2002
Service
For all Models arriving at your dealership with

transportation wiper blades:
Transportation wiper blades (except A6 and A4

Models, see notes below) are shorter than
original equipment wiper blades and colored blue
or yellow.
Note:
Until further notice, A6 Models will be equipped

with a set of original equipment blades (to be
used as transportation blades).
A new set of wiper blades are located in the

trunk and must only be installed at time of
vehicle delivery.
For all Models except A6 and A4, original

equipment blades are temporarily installed then
removed during the Pre-Delivery Inspection
(PDI) to check wiper blade park position only.
For A4 Models, the transportation wiper blades

(yellow) slide over the original equipment
blades (already installed on the wiper arms).
To ensure customer satisfaction, leave

transportation wiper blades on vehicle until time
of retail vehicle delivery.
101
Transportation wiper blades, removing
Transportation blades can easily be removed as

follows:
- Grasp blade as shown and rotate in direction of arrow (toward

windshield).
- Rotate blade in opposite direction (black arrow) then, carefully slide

blade off wiper arm.
Note:
Wiper arm/blade alignment has been preset at the factory, then checked
and adjusted (if necessary) during the PDI.
DO NOT twist or bend the wiper arm. If wiper arm/blade alignment is

incorrect, chattering and/or streaking will occur.
Transportation wiper blades, removing (A4)
-
New style original equipment blade (already installed on wiper arms),
to remove slide transportation blades off original equipment wiper

blades.
102
If arm has been bent:

Group 92
- Install original equipment wiper blades (located

in trunk) at the time of retail vehicle delivery.
Note:
Wiper blade with air deflector (arrow) must be installed on driver's side
with deflector on bottom of wiper blade.
Passenger's side wiper blade may be curved, install with curved ends
of blade pointing up.
Wiper blades, installing (A4)
No action necessary after removing transportation blades.
103
Underbody closeout cover, installing at

Perfect Delivery Inspection (PDI)
To my 2002
Condition
New vehicles must have the rear under body close-out cover installed
during the PDI.
Covers were removed to access tie down cavities for transportation

purposes.
Production
Beginning Jan. 2002, new close-out covers (with holes for tie down
access) will be installed.
Service
Note:
Due to the vehicle pick up points, to ease installation of the close-out

covers, the use of a drive on hoist (i.e. alignment hoist) may be required.
- Install rubber body plugs into vehicle tie down cavity (arrow).
Note:
Failure to install rubber plugs into tie down cavity will cause wind/road
noise inside vehicle.
104
- Remove rear close-out cover plastic nuts and

retainer pins.
- Install covers by carefully manipulating them into place.
- Front of covers (white arrow) must be between larger body cover (black
arrow) and body.
- Reinstall retainer pins.
105
- Reinstall close-out cover plastic nuts.
When procedure applies to vehicles within the New Vehicle Limited Warranty, use the following:
Part Identifier: 5324
Labor Operation: 53242400 20TU
Engine, removing and installing Page 1 of 20
10-1
Engine, removing and

installing
Rules of cleanliness
CAUTION!
Whenever carrying out work on the fuel

supply and fuel injection systems, carefully
observe the following five rules of
cleanliness.
1 - Thoroughly clean fuel system line and hose

connections and the surrounding area before
disconnecting.
2 - Place removed components on a clean

surface and cover. Use plastic sheeting or paper.
Do not use fluffy rags that could leave lint!
3 - Carefully cover over or seal any components

that have been opened if repairs are not carried
out immediately.
4 - Install only clean parts:
Do not remove replacement parts from the

packaging until immediately before they are to
be installed.
Do not use parts that have been stored without

packaging (e.g. in toolboxes, etc.).
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.GE01.10.1 11/21/2002
5 - When the fuel system is opened:
Avoid working with compressed air whenever

possible.
Avoid moving the vehicle if possible.
10-2
Safety precautions
WARNING!
Be sure the ignition is switched OFF, when:
Disconnecting ignition wires
Disconnecting fuel injection system wiring
Connecting or disconnecting test equipment

leads
Disconnecting the battery
Washing the engine or engine

compartment.
CAUTION!
BEFORE disconnecting the battery:
Stop the engine.
Be sure the ignition is switched OFF (also

applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).
Be sure of the proper radio code (for vehicles

equipped with coded anti-theft radio).
10-3
Removing
The engine is removed from the front, after being

separated from the transmission.
CAUTION!
Determine correct radio anti-theft coding

before disconnecting the battery.
Note:
All tie wraps that are loosened or removed in

order to remove the engine must be replaced or
reinstalled in the same place when the engine is
installed.
- Disconnect battery Ground (GND) strap.
- Unbolt bumper by unclipping vent grille at left

and right and removing from bumper
Repair Manual, Body Exterior, Repair Group

63 .
- Remove noise insulation panel.
10-4
- Unbolt cooling coil for power steering fluid at

bottom left of radiator.
- Drain coolant at radiator.

- Remove locking element for connection flange of coolant hose at
bottom of radiator; pull off connection flange.
10-5
- Remove intake air duct to air cleaner at air

scoop and lift out.
- Disconnect harness connectors for headlights and turn signal lights.

- Disconnect harness connector of engine coolant temperature sensor
near bottom coolant hose at left of radiator.
- Disconnect four harness connectors at ABS hydraulic unit.

- Disconnect harness connectors for anti-theft warning system at upper
left of front end.
- Disconnect coolant hose at top left of engine.
- Unclip and disconnect A/C clutch harness connectors at radiator air
guide on lower right.
- Disconnect harness connectors at both horns, let cables hang free.
- Remove air scoop.
10-6
- Disconnect harness connectors at Mass Air

Flow (MAF) sensor and Idle Air Control (IAC)
valve, unbolt hose from plenum chamber and
unclip.
- Disconnect hose connection at IAC valve.
- Remove air guide between air cleaner and

throttle body.
- Remove air cleaner housing.
- Disconnect fuel supply and return lines.
- Remove coolant expansion tank.
- Remove cover for electronics box.

- Unclip engine control module and disconnect harness connectors.
- Disconnect harness connectors at connector station below engine
control module.
- Disconnect ground connection and bracket for harness connectors at
plenum chamber.
- Disconnect both coolant lines to heater core between plenum chamber
and engine.
- Disconnect accelerator pedal cable and let hang free.
- Disconnect both harness connectors at top of transmission.
10-7
- Loosen V-belt for hydraulic pump, viscous fan

and generator and secure with special tool 3204.
- Use screwdriver to counter-hold belt pulley for

viscous fan and unbolt with open-end wrench
3312.
Tightening torque with torque wrench 1331 and

open-end wrench 3312 is 37 Nm (27 ft lb);
without open-end wrench 3312 tightening torque
is 70 Nm (52 ft lb).
Note:
Refer to table for torque wrenches of a different

length; length of torque wrench from socket drive
to center of handle.
Length of torque Tightening

wrench torques
220 mm 33 Nm (24 ft lb)
280 mm 37 Nm (27 ft lb)
300 mm 39 Nm (29 ft lb)
440 mm 45 Nm (33 ft lb)
10-8
- Unbolt hydraulic pump from mounting bracket.
CAUTION!
Hydraulic lines should remain connected.
- Unscrew bolts and secure A/C compressor to

one side with wire.
CAUTION!
Disconnect at mounting points only.
DO NOT open the air conditioning refrigerant

circuit.
Set the A/C compressor aside carefully.

Refrigerant lines kink easily.
The A/C refrigerant circuit must only be

opened by specially trained technicians
using the proper tools and equipment.
- Remove bolts securing exhaust manifold and

front exhaust pipe at top.
- Disconnect battery positive (B+) cable from

starter at right of engine below exhaust manifold.
- Remove starter, take off insulator at starter

positive (B+) connection, unbolt fixture at engine
block, disconnect ground wire from engine
support.
- Unscrew four engine mounting bolts.
10-9
- Support weight of transmission using engine

support bridge 10-222A.
- Attach engine support adapter 3147 to bolt hole of transmission bell

housing.
(Adapter installation shown with engine removed)
- Attach engine sling 2024A to engine and workshop crane 1202A.
CAUTION!
The mounting hooks and pins on the lifting device must be secured
with locking pins.
10-10
Mounting engine cylinder block on assembly

stand
- Mount engine to stand using holding fixture VW 540 along with VW

540/2.
CAUTION!
DO NOT have the cylinder block mounted to the assembly stand

while measuring the cylinder bores (Repair Group 13). The cylinder
block is deformed by its own weight under these conditions and
such stress will result in false measurements that are not accurate
after the tension has been relieved.
10-11
Installing
The engine is installed in the reverse order of

removal, with the addition of the following special
conditions and steps:
WARNING!
Do not re-use any fasteners that are worn or

deformed in normal use. Many fasteners are
designed to be used only once and become
unreliable and may fail when used a second
time. This includes, but is not limited to, nuts,
bolts, washers, self-locking nuts or bolts,
circlips and cotter pins. Always follow
recommendations given in this publication.
Always replace these fasteners with new
parts.
- Check that alignment sleeves for centering

engine and transmission are properly installed in
cylinder block. Install sleeves if necessary.
- Always install new seals and gaskets.
- Check centering of clutch disc, if necessary.
- Check clutch release bearing for wear and

replace if necessary.
- Clean transmission input shaft splines. Lightly

lubricate clutch release bearing and
transmission input shaft splines with G 000 100
grease. Do not grease guide sleeve for release
bearing.
- Install engine mounts free of stress. To do so,

align engine by shaking before tightening engine
mounts.
10-12
- Allow stop of torque support to move down onto

rubber block under its own weight; tighten bolts
to 45 Nm (33 ft lb).
- Align exhaust system free of stress Repair

Group 26.
- Adjust accelerator pedal cable Repair Group

20.
- Re-fill engine cooling system Repair Group

19.
- Drained coolant may only be re-used provided

the cylinder block or the cylinder head was not
replaced.
- Check oil level before starting engine.
- Short blocks are supplied without bushing in

crankshaft. For vehicles with automatic
transmission, tap bushing into place before
installing drive plate.
- Check reconditioned engines with manual

gearbox to determine whether needle bearing is
installed in crankshaft; install if necessary.
- Observe tightening torque specifications.
10-13
Tightening torques
Notes:
The tightening torques apply only to lightly

greased, oiled, plated or specially treated nuts
and bolts.
It is permissible to use additional lubricants

such as engine or gear oils, but do not use
Molykote and do not use degreased parts.
Permissible tolerance for tightening torques

15%.
Bolts, nuts M6 10 (7 ft
Nm lb)
M8 20 (15 ft
Nm lb)
M10 45 (33 ft
Nm lb)
M12 60 (44 ft
Nm lb)
Exhaust pipe to manifold M8 25 (18 ft

Nm lb)
AC compressor to bracket M8 25 (18 ft
Nm lb)
Torque converter to drive M8 35 (26 ft
plate Nm lb)
Engine support to engine M10 45
mount Nm
Viscous coupling to M10 45 (33 ft
bracket Nm lb)
Hydraulic pump to bracket M8 25 (18 ft
Nm lb)
Generator to mounting M8 35 (28 ft
bracket Nm lb)
Ribbed belt and pulley, assembly Page 1 of 1
13-3
Ribbed belt and pulley,

assembly
1 - Tensioner
Loosening page 13-9
2 - 55 Nm (41 ft lb)
3 - 20 Nm (15 ft lb)
4 - Ribbed belt
Removing and installing page 13-9
5 - Belt routing for vehicles w/o A/C
Not applicable for USA/Canada
6 - Bolt
Always replace
Oil threads
Use only new double hex head (12-pt.) cap
screw grade 9.8
Tightening torque (bolt oiled): 200 Nm (148
ft lb) plus additional 1/2-turn (180 ); two
1/4-turns (90 ) are permissible
7 - 20 Nm (15 ft lb)
Engine, disassembling and assembling Page 1 of 38
13-1
Engine, disassembling and

assembling
3369 support tool
1 - Bolts
45 Nm (33 ft lb)
2 - Bolts
45 Nm (33 ft lb)
3 - Bolts
10 Nm (7 ft lb)
4 - Bolts
10 Nm (7 ft lb)
5 - Bore
For 3369 support tool
6 - Lock carrier bore
7 - Fender bore
13-2
- Remove front bumper.
- Remove 3 quick-release screws on front of noise

insulation panel.
- Unbolt air guide between lock carrier and air filter
at lock carrier.
- If installed, remove retaining clamps for wiring
harness on left side of radiator frame.
- Remove bolt -2- and install 3369 support tool.
- Install 3369 support tool into left bore -5-.
- Remove bolts -4- and pull lock carrier out to
stop.
- To secure lock carrier, install appropriate M6
bolts into rear bored holes of lock carrier -6- and
fender -7-.
13-3
- After installing lock carrier, check wiring for

proper routing near coolant fan.
- Install front bumper.
13-4
Ribbed belt for power steering pump,

generator and viscous fan, and V-belt for
coolant pump
CAUTION!
Before removing ribbed belt, note direction of

rotation with chalk or felt-tip marker. Reversing
the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt,
make sure it is seated correctly on the pulley.
1 - Fan wheel bolt

10 Nm (7 ft lb)
2 - Fan wheel
For viscous fan
Removing and installing Page 13-14 ,
Fig. 1
3 - Coolant pump pulley bolt
25 Nm (18 ft lb)
4 - Belt pulley
For coolant pump
V-belt design
Installed position: straight side toward
coolant pump
13-5
5 - Ribbed belt
Removing and installing Page 13-15
Check for wear
6 - Special bolt
Tighten to 40 Nm (30 ft lb)
Only use VW bolts, bolt strength grade
10.9 parts catalog
With pulley for ribbed belt
Installation only possible in one position
Page 13-14 , Fig. 2
8 - Bolt for ribbed belt tensioner
25 Nm (18 ft lb)
9 - Ribbed belt tensioner
To release tension on the ribbed belt, use
open-end wrench Page 13-15
Secure with appropriate hex socket or
3204 drift in positioning bore
10 - Belt pulley
For viscous fan
Fig. 1
13-6
11 - Circlip
For viscous fan bearing
12 - Bolt for belt pulley
10 Nm (7 ft lb)
13 - Bearing
For viscous fan
14 - T-head bolt
Insert before installing bracket for
generator, power steering pump and
viscous fan
15 - Nut
40 Nm (30 Nm)
16 - Bolt
25 Nm (18 ft lb)
13-7
17 - Generator
Removing:
- Disconnect battery Ground (GND) strap.
- Loosen ribbed belt and remove from
generator Page 13-15 .
- Remove air guide at throttle body.
- Remove upper and lower threaded
assemblies.
- Swing generator slightly to side and
remove lower bolt.
- Remove wiring from generator.
- Remove generator.
Note:
For easier installation of generator into the bracket,

push back lower bolt bushing slightly.
18 - Bolt
40 Nm (30 ft lb)
19 - Bolt
40 Nm (30 ft lb)
20 - Brace
To cylinder block
21 - Bolt
25 Nm (18 ft lb)
13-8
22 - Brace
For intake manifold
23 - Bolt
20 Nm (15 ft lb)
24 - Bolt
40 Nm (30 ft lb)
25 - Bolt
25 Nm (18 ft lb)
26 - Bolt
25 Nm (18 ft lb)
27 - Bracket
For generator, power steering pump and
viscous fan
Different length bolts
Arrangement and tightening sequence
Page 19-16
Removing and installing Repair Manual,
Suspension, Wheels, Steering, Repair
Group 48
29 - Bolt
25 Nm (18 ft lb)
13-9
30 - Coolant pump
With coolant regulator
31 - Belt pulley
For power steering pump
Designed for ribbed belt
Install with bulged side facing in driving
direction
32 - Belt pulley
Designed for ribbed belt
33 - Bolt
25 Nm (18 ft lb)
34 - V-belt
For coolant pump
35 - Viscous clutch
Fig. 1
13-10
Ribbed belt for air conditioning
CAUTION!
The A/C refrigerant circuit must not be

opened.
rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt. When installing the
ribbed belt, make sure it is seated correctly
on the pulley.
1 - Bolt
25 Nm (18 ft lb)
2 - Refrigerant lines
Do not unbolt or separate
3 - Bushing
Verify proper seating in bracket
4 - Bolt
For bolt strength grade 8.8, tighten to 25
Nm (18 ft lb) parts catalog
For bolt strength grade 10.9, tighten to 30
Nm (22 ft lb) parts catalog
13-11
5 - Bracket
For A/C compressor
7 - Washer
8 - Bolt
20 Nm (15 ft lb)
9 - Ribbed belt
Check for wear
10 - A/C compressor
After removing, secure A/C compressor to
long member (i.e. using wire).
CAUTION!
Do not let A/C compressor hang by refrigerant

lines.
11 - Washer
13-12
V-belt and ribbed belt, routing overview

2 - Generator
3 - Viscous clutch
4 - Coolant pump
6 - V-belt
For coolant pump
7 - Ribbed belt
For generator, power steering pump and
viscous fan
13-13
For A/C compressor
10 - Ribbed belt
For A/C compressor
11 - A/C compressor
13-14
Fig. 1 Viscous fan, removing and installing

Lock carrier in service position Page 13-1
Ribbed belt free of tension Page 13-15

- Secure belt pulley for viscous fan with 5 x 60 mm bolt and remove
using hex socket wrench.
- When installing viscous fan, tighten to 45 Nm (33 ft lb).
Fig. 2 Install vibration damper

Ribbed belt removed Page 13-15

- Install vibration damper using only original equipment bolts (bolt
strength grade 10.9) parts catalog.
Installation is only possible in one position: the bore hole of the vibration
damper (arrow) must align with raised portion of toothed belt gear.
- Tighten vibration damper bolts to 40 Nm (30 ft lb).
13-15
Ribbed belt, removing and installing
CAUTION!

on the pulley.
Removing
- Remove noise insulation panel (arrows).
- Loosen bolts for ribbed belt tensioner for A/C compressor (arrows).
- Release tension on ribbed belt and remove belt.
13-16
All models
- Move ribbed belt tensioner in direction of arrow to release tension on

ribbed belt.
Note:
Ribbed belt tensioner can be locked in place by inserting a proper sized

angled hex socket wrench (arrow) or 3204 drift into locating bore.
- Remove ribbed belt and release tension on ribbed belt tensioner.
13-17
Installing
Note:
When installing ribbed belt, make sure it is

seated correctly on the pulley.
- Place ribbed belt on belt pulleys for crankshaft,

viscous fan and power steering pump, (use tools
to pull up if necessary).
- Move ribbed belt tensioner in direction of arrow.

- Install ribbed belt on belt pulley for generator last and release tension
on belt tensioner.
- Check ribbed belt for proper installation.
Ribbed belt routing Page 13-12
- Install ribbed belt for A/C compressor.
Ribbed belt routing Page 13-12
- Use torque wrench to pre-tighten belt tensioner hex screw to 25 Nm

(18 ft lb).
- Tighten bolts -A- to 20 Nm (15 ft lb) at same time.
- Start engine and check running of belt.
13-18
V-belt, removing and installing
Lock carrier in service position Page 13-

17
Ribbed belt free of tension Page 13-15
Removing

- Remove viscous fan (with belt pulley) from bearing Page 13-14 , Fig.
1.
- Remove belt pulley for coolant pump. Use drift (arrow) to counterhold
at belt pulley for power steering pump.
- Remove V-belt.
13-19
Installing
Installation is the reverse of removal, noting the

following:
- Install V-belt and loosely bolt both halves of belt

pulley to coolant pump.
- Slowly bring belt pulley halves together by

turning coolant pump and tightening bolts for
belt pulley in stages.
While tightening pulley halves, the V-belt must

move outward and sit correctly on belt pulley.
- Tighten bolts to 25 Nm (18 ft lb).
Note:
Adjustment of V-belt tension for coolant pump is

not possible.
- Install ribbed belt and release tension on

tensioner.
- Start engine and check running of belt.
- Check tightening torque of bolts for coolant

pump belt pulley.
13-20
Bearing for viscous fan in mounting

bracket, removing and installing
Hex nut from 3301 assembly tool
Extractor pipe from 3350 installation device
3367 press out tool for viscous clutch fan

bearing bushing
Removing
- Remove ribbed belt Page 13-15 .
- Remove viscous fan (together with belt pulley)

Page 13-14 , Fig. 1 .
- Remove circlip (arrow) from bearing bushing.
13-21
- Pull bearing from bracket using hex nut from 3301 assembly tool, bolt
from 3367 press out tool for viscous fan bearing bushing and 3350
extractor pipe.
Installing
Installation is the reverse of removal, noting the following:
- Press in bearing using 3367 press out tool for viscous fan and hex nut
from 3301 assembly tool.
- Using circlip pliers, install circlip in viscous fan bracket.
- Install viscous fan Page 13-14 , Fig. 1.
13-22
Mounting bracket for generator, power

steering pump and viscous fan,
removing and installing
Removing
CAUTION!
Before disconnecting the battery, determine

the correct coding for the anti-theft radio.
- Switch ignition off and disconnect battery Ground (GND) strap.

- Remove ribbed belt and ribbed belt tensioner Page 13-18 .
Note:
Ribbed belt for A/C remains installed.
Ribbed belt, removing Page 13-15 .
- Remove belt pulley for power steering pump.

- Unbolt power steering pump from mounting bracket for generator,
power steering pump and viscous fan and tie to side.
All lines remain connected
13-23
- Follow procedures for "Coolant pump, removing

and installing" Page 19-13 .
Note:
Coolant pump is bolted to mounting bracket for

generator, power steering pump and viscous fan.
Installing
Installation is the reverse of removal, noting the

following:
- Replace O-ring for coolant pump (to guard

against leakage).
Tightening torques
Component Tightening
torque
Belt pulley to power steering 25 Nm (18 ft
pump lb)
Power steering pump to mounting
bracket for generator, power
steering pump and viscous fan 25 Nm (18 ft
lb)
13-24
Toothed belt, overview
CAUTION!
Before removing toothed belt, note direction of

rotation with chalk or felt-tip marker. Reversing
the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt,
make sure it is seated correctly on the pulley.
1 - Bolt
10 Nm (7 ft lb)
2 - Bolt
10 Nm (7 ft lb)
3 - Bolt
10 Nm (7 ft lb)
4 - Bolt
20 Nm (15 ft lb)
5 - Upper toothed belt cover
To remove, unbolt ribbed belt tensioner
When installing, carefully hook into lower
toothed belt cover
13-25
6 - Toothed belt
Before removing, note direction of rotation
using chalk or felt-tip marker
Check for wear
Removing Page 13-29
Installing (adjusting valve timing) Page
13-32
7 - Bolt for tensioner
25 Nm (18 ft lb)
8 - Nut
10 Nm (7 ft lb)
9 - Washer
10 - Bolt
65 Nm (48 ft lb)
Use 3036 retainer for loosening and
tightening
11 - Washer
12 - Camshaft gear
For exhaust camshaft
For removing and installing, remove
toothed belt Page 13-29
Installation position Fig. 1
13 - Tensioner
13-26
14 - Connecting bolt
25 Nm (18 ft lb)
For tensioner
15 - Rear toothed belt cover
16 - Bolt
20 Nm (15 ft lb)
17 - Intermediate shaft gear
18 - Washer
19 - Toothed belt gear for crankshaft
Contact surface between toothed belt gear
and crankshaft must be free of oil
Installation only possible in one position
20 - Bolt for toothed belt gear for crankshaft
Always replace
90 Nm (66 ft lb) + additional 1/4 turn (90 )
Do not oil
Use 3099 retainer for loosening or
tightening
Attach 3099 retainer Page 13-39
To secure retainer, remove torque support
bracket Page 17-2 , item 5
13-27
21 - Bolt
65 Nm (48 ft lb)
Use 3036 retainer when loosening or
tightening
22 - Toothed belt tensioner
23 - Bolt
10 Nm (7 ft lb)
24 - Idler pulley
25 - Bolt
25 Nm (18 ft lb)
26 - Lower toothed belt cover
To remove, remove vibration damper
13-28
Fig. 1 Installation position for camshaft gear
Thin rib of camshaft gear points outward (arrows) and TDC Cyl. 1 marking
is visible.
13-29
Toothed belt, removing and installing
Removing
Engine installed
V159 pin wrench
- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .
- Remove viscous clutch (with belt pulley) Page

13-14 , Fig. 1 .
- Remove upper toothed belt cover.
CAUTION!
Before removing toothed belt, note direction

of rotation with chalk or felt-tip marker.
belt can destroy the belt.
- Turn crankshaft at central bolt of toothed belt gear in direction of

engine rotation to TDC Cyl.1 marking (arrows).
13-30
- Remove vibration damper.
- Remove lower toothed belt cover (arrows).
13-31
- Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).
- Push toothed belt tensioner downward.
- Remove toothed belt.
13-32
Installing (adjust valve timing)
Note:
Use the following procedure to adjust toothed

belt, even for repairs that only require removal
of toothed belt from camshaft gear.
Adjustments can be made on a hot or cold

engine.
CAUTION!
When turning camshaft, crankshaft may not

be at TDC for any cylinder. Valves and/or
piston heads may be damaged.
- Align marking on camshaft gear to marking on cylinder head cover.

- Place toothed belt on crankshaft gear noting direction of rotation.
- Install lower toothed belt cover.
- Using a bolt, secure vibration damper/belt pulley (note locating point).
- Set crankshaft to TDC Cyl. 1 position.
- Place toothed belt on belt tensioner and camshaft gear.
13-33
- Tighten toothed belt by turning tensioner -A- to right using 2 pin

spanner (i.e. Matra V159 pin wrench) until cylinder -1- is fully extended
and tensioner -2- is raised by approx. 1 mm.
- Tighten mounting bolt -3- hand tight.
- Turn crankshaft 2 rotations in running direction.
- Check area -A- for proper alignment with the upper edge of piston -2-
(Fig. A13-0012) and adjust if necessary.
Area -A-: adjustment OK
Area -B-: wear limit
Area -C-: re-adjust and check belt drive including tensioner for
wear
Note:
If edge of piston is located in area -A-, measurement -D- is between 25-29

mm (0.984-1.142 in.).
13-34
- Counterhold toothed belt tensioner using 2 pin spanner -B- and tighten
mounting screw -3-.
- Turn crankshaft at central bolt for toothed belt gear two rotations in
direction of engine rotation, until camshaft and crankshaft markings
align with their respective reference points.
- Install vibration damper/belt pulley.
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner Page 13-17 .
Note:
When installing the ribbed belt, make sure it is seated correctly on the
pulley.
13-35
Tightening torques
torque
Toothed belt tensioner to
tensioner assembly
25 Nm (18 ft
lb)
Lower toothed belt cover M6 10 Nm (7 ft lb)
to
cylinder block
M8 20 Nm (15 ft
lb)
Vibration damper/belt pulley to
crankshaft
40 Nm (30 ft lb)
1)
Ribbed belt tensioner to

mounting bracket
25 Nm (18 ft
lb)
1) Bolt strength grade: 10.9
Engine, disassembly and assembly Page 1 of 13
13-1
Engine, disassembly and

assembly
Removing
- Remove noise insulation -arrows-.

- Remove bumper
- Move lock carrier to service position
- Remove viscous fan (counter-hold with pin wrench 3212).
Note:
Viscous fan has left-hand thread: turn in direction indicated.
13-2
- Mark direction of rotation of ribbed belt.
- To slacken ribbed belt, turn to the right using a 17 mm ring spanner

until the two holes are aligned with each other -arrow- and hold in
position with mandrel 3204.
Note:
Mark the direction of rotation of the ribbed belt with chalk or felt pen
before removing. A used belt can break if it rotates in the opposite
direction when reinstalled.
- Take off ribbed belt.
13-3
Installing
- Install ribbed belt onto crankshaft pulley and idler wheel first, and push
belt onto tensioning roller last.
Routing of ribbed belt
D1 - vehicles without air conditioner

D2 - vehicles with air conditioner
- Take out mandrel 3204.
- Counter-hold belt pulley for viscous fan using spanner wrench 3212
and tighten viscous fan using open end spanner 3312 and torque
wrench 1331 (left hand thread).
Note:
Viscous fan has left-hand thread: turn against direction indicated.
- Install lock carrier.
- Install bumper.
- Install noise insulation.
13-4
Removing
- Remove bolts -arrows- and remove engine cover panel -C-.
- Remove pressure hoses -arrows- between charge air coolers and

pressure pipes (left and right sides).
13-5
- Remove pressure pipes -1-.
Note:
Watch position of retaining strips -2-.
- Remove tensioner -1- for ribbed belt.

- Remove left and right toothed belt guards -2-.
- Remove center toothed belt guard -3-.
13-6
- Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
Note:
Turn over the engine at the central bolt on the crankshaft.
- Check position of camshafts: larger holes in securing plates on

camshaft sprockets must align opposite one another on inside. If not,
turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
- The TDC drilling in the crankshaft must be visible (or able to be felt) in
line with the sealing plug hole.
CAUTION!
Injury risk - do not turn engine while feeling for TDC drilling.
- Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
13-7
- Remove vibration damper on crankshaft.
Note:
The central bolt does not have to be loosened to remove the vibration
damper.
- Remove idler wheel for ribbed belt -arrows-.

- Remove toothed belt guard behind vibration damper -arrows-.
13-8
Note:
Mark the direction of rotation of the toothed belt

with chalk or felt pen before removing. A used
belt can break if it rotates in the wrong direction
when reinstalled.
The toothed belt tensioning element is oil-

damped and can therefore only be compressed
slowly by applying constant pressure.
- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm
in direction of arrow until tensioning lever -2- compresses tensioning
element -3- sufficiently to enable special tool T 400 11 to be fitted in
drilling and in plunger.
- Insert special tool T 400 11, release toothed belt tensioning roller.
- Take off toothed belt.
13-9
Installing
- Insert camshaft clamp 3391 in securing plates of

two camshafts.
- Slacken both camshaft bolts and remove

approx. 5 turns.
- Take out camshaft clamp 3391.
- Pull off both camshaft sprockets with special tool T40001.

- Reinstall both camshaft sprockets with securing plates and tighten
hand-tight again.
Note:
The camshaft sprockets should be just tight enough on the camshaft

tapers so that they can still be turned but do not move axially.
- Install toothed belt on all sprockets as illustrated.

- Install camshaft clamp 3391.
13-10
- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm
in direction of arrow until special tool T 400 11 can be removed.
- Pre-tension toothed belt by a turning in direction of arrow with a torque

of 15 Nm using a torque wrench.
- Tighten bolts on camshaft sprockets.
13-11
- Install idler wheel for ribbed belt -arrows-.

- Install toothed belt guard behind vibration damper -arrows-.
- Install vibration damper. Note positions of locating lugs -arrows- on belt

sprocket.
13-12
- Install toothed belt guard.
- Install ribbed belt Page 13-3 .
Tightening torques
Toothed belt sprocket to 55 Nm
camshaft
Idler wheel 45 Nm
Toothed belt tensioning roller 20 Nm
Pulley to crankshaft 20 Nm
Toothed belt tensioning 10 Nm
element
Central bolt 1) to crankshaft 200 Nm + 180

2)
1) The central bolt must always be replaced.
2)Turning in two stages of 90 is also

permissible.
13-13
Vibration damper, removing and

installing
Note:
The central bolt does not have to be loosened to

remove the vibration damper.
- When installing, ensure that notches -arrows- in vibration damper are

aligned with locating lugs on toothed belt sprocket.
Tightening torque: 25 Nm
13-1

assembling
Lock carrier, moving into service
position
Special tool 3369
13-2
1 - 45 Nm
2 - 45 Nm
3 - 10 Nm
4 - 10 Nm
5 - Bore
For special tool 3369
6 - Hole in lock carrier
7 - Bore in fender panel
13-3
Removing
- Remove sound insulation Fig. 1, Page

13-6
- Remove front bumper:
- Remove lower air duct hose to charge air cooler

Fig. 2, Page 13-6
- Remove air duct between lock carrier and air
filter Fig. 3, Page 13-7
- Remove retaining clips (if installed) for wiring
harness on left at radiator shroud.
13-4
- Remove bolt -2- and screw in special tool 3369.

- Screw in special tool 3369 into bore -5-.
- Remove bolts -4- and pull lock carrier out as far
as it will go.
- Secure lock carrier with suitable M6 bolts in hole
-6- (lock carrier) and hole -7- (fender panel).
13-5
Installing
Installation is carried out in the reverse order of

removal; note the following:
- When lock carrier has been installed, check that

wiring next to radiator is correctly routed.
- Adjust limit stop for torque reaction support
Fig. 4, Page 13-7 .
- Adjust headlights.

Group 94
13-6
Fig. 1 Remove front sound insulation

- Remove sound insulation -arrows-.
Fig. 2 Remove air duct hose

- Remove air duct hose to bottom left charge air cooler from lock carrier -
arrow-.
13-7
Fig. 3 Remove air duct between lock carrier and air filter
- Remove bolts -arrows-.
- Remove air ducts -1- and -2-.
Fig. 4 Adjust stop for torque reaction support

- Attach limit stop for torque reaction support to rest on rubber buffer for
torque reaction support under its own weight, and tighten bolts -arrows-
to 28 Nm.
13-8
Ribbed belt drive for power steering pump,

Generator and viscous fan
Note:
Mark the direction of rotation with chalk or felt pen

before removing the ribbed belt. If the belt rotates in
the wrong direction when it is reinstalled, belt
breakage may result. Ensure that the belt is
properly seated on the pulleys when installing.
1 - 10 Nm.
2 - Fan wheel
For viscous fan
Removing and installing Page 13-21 .
3 - Circlip
For viscous fan bearing
13-9
4 - Ribbed V-belt
Check for wear
Routing of ribbed belt Fig. 2, Page
13-17
5 - Bolt (special type)
Always replace
Use only genuine bolts
Parts List
Torque: 10 Nm + 90 (1/4 turn)

With pulley for ribbed belt
Can only be installed in one position Fig.
1, Page 13-17
7 - Pulley
For viscous fan
13-10
8 - 23 Nm
9 - Tensioner for ribbed belt
Turn with open end spanner to loosen
ribbed belt Page 13-18 .
Hold in position by inserting a suitable pin
or Allen key in holes.
10 - 46 Nm
11 - Mounting
For viscous fan
12 - Bracket
For Generator, power steering pump and
viscous fan
13 - 23 Nm
13-11
14 - Generator
Removing:
- Disconnect battery Ground strap
- Remove air duct hose to charge air
cooler.
- Loosen ribbed belt and take belt off
Generator Page 13-18 .
- Remove viscous fan and put into radiator
cowl.
- Remove electrical wiring from Generator.
- Loosen connections for Generator from
top and bottom and remove Generator.
Installing:
- To facilitate attachment of Generator
slightly drive back thread bushing for
securing bolt at bracket.
13-12
15 - 45 Nm
16 - Support
For intake manifold
17 - 20 Nm
18 - 52 Nm
Apply D 000 600 when installing
Bolts have different lengths. For positions
and tightening sequence Page 13-33
19 - 23 Nm
Removing and installing:

Repair Group 48
21 - 23 Nm
13-13
22 - Pulley
Installation position: Open side faces to
front of vehicle
23 - 23 Nm
24 - Ribbed bolt - 28 Nm
25 - Viscous coupling
13-14
Ribbed belt drive for air conditioner -

assembly overview
CAUTION!
The air conditioner refrigerant circuit must not

be opened.
Note:

before removing the ribbed belt. If the belt rotates in
the wrong direction when it is reinstalled, belt
breakage may result. Ensure that the belt is
1 - Bracket
13-15
2 - Air conditioner compressor

Do not loosen or disconnect refrigerant
hoses or lines.
After removing compressor from
mountings, secure to chassis side member
with wire or similar. Do not leave
compressor suspended on refrigerant
hoses.
3 - Dowel sleeve
Check sleeve is correctly seated in bracket
4 - 33 Nm
5 - Bracket
For A/C compressor
6 - Tensioner
For ribbed belt
Removing and installing ribbed belt
Page 13-18
13-16
7 - Washer
8 - 23 Nm
9 - Ribbed V-belt
Check for wear
Do not kink
Routing of ribbed belt Fig. 2, Page
13-17
10 - Washer
11 - 25 Nm
12 - Retaining clip
13 - 20 Nm
13-17
Fig. 1 Installing vibration damper

Lock carrier must be in service position Page 13-1 .
Ribbed belt must be removed Page 13-18 .

Always replace bolts. Only use original type bolts to install the
vibration damper.
Parts List
The vibration damper can only be installed in one position. The hole -
arrow- in the vibration damper must fit over the projection on the toothed
belt sprocket.
- Tighten bolts of vibration damper to 10 Nm + 90 (1/4 turn).
Fig. 2 Ribbed belt routing
13-18
Note:
Mark the direction of rotation with chalk or felt

pen before removing the ribbed belt. If the belt
rotates in the wrong direction when it is refitted,
belt breakage may result. Ensure that the belt is
Removing
- Remove sound insulation -arrows-.
- Loosen bolts securing ribbed belt tensioning roller for A/C compressor -
arrows-.
13-19
- Turn tensioner in direction of arrow to loosen ribbed belt.

- Remove ribbed belt from Generator and release tensioner.
Note:
When the lock carrier is in the service position, the ribbed belt tensioner
can be secured to prevent it from turning by inserting a suitable pin or
Allen key -arrow- into the holes.
13-20
Installing
- Attach ribbed belt to pulleys from crankshaft and

vane pump and, if necessary, pull up with
auxiliary tool.
- Swivel tensioner for ribbed belt in direction of arrow.

- Install ribbed belt over Generator pulley last. Release tensioner.
- Check that ribbed belt is properly seated.
- Fit ribbed belt for A/C compressor.
Ribbed belt routing Fig. 2, Page 13-17
- Attach torque wrench at "7 o'clock position" as illustrated to hex on

tensioner and pretension to 30 Nm.
- While tensioning, tighten bolts -A- to 23 Nm.
- Start engine and check belt running.
13-21
Viscous fan, removing and installing
Removing
Lock carrier must be in service position

Page 13-1 .
- To loosen ribbed belt, turn tensioner in direction of arrow.

- Remove ribbed belt from Generator pulley.
- Secure pulley for viscous fan with pin punch -1- and remove using
Allen key -2-.
13-22
Installing

- Install lock carrier Page 13-1 .
Tightening torque
Component Nm
Viscous fan to bearing 45
13-23
Bearing for viscous fan, removing and

installing
Special tool 3301

Special tool 3350
Special tool 3367
13-24
Removing

Page 13-1 .
- Remove air duct hose -1-.
Note:
Connector -2- remains plugged in.
- Turn tensioner in direction of arrow to loosen ribbed belt.

13-25
Allen key -2-.
- Remove viscous fan from mounting.
- Remove intake pipe support -arrows-.
13-26
- Remove circlip -arrow- from bearing bushing using angled circlip pliers.
- Remove bearing from housing with nut from assembly mounting 3301,
bolt 3367/3 and pipe 3350.
13-27
Installing
Installation is carried out in the reverse order;

note the following:
- Press in bearing with tool 3367 and nut from assembly mounting 3301.
- Install circlip in housing for viscous fan using angled circlip pliers.
- Install viscous fan Page 13-21 .
13-28
Bracket for Generator, power steering

pump and viscous fan, removing and
installing
Removing
- Observe or obtain radio anti-theft code on

vehicles with coded radio.
- Disconnect Ground strap at battery with ignition

switched off.
- Remove cover from power steering fluid

reservoir.
- Mark connectors -1 to 5- and remove from bracket.
13-29
- Unclip connector bracket at ABS unit console and lift up to remove.
- Remove air duct hose -1-.
Note:
Connector -2- remains plugged in.
13-30
- To loosen ribbed belt, turn tensioner in direction of arrow.

Allen key -2-.
- Remove viscous fan from mounting and put in front of radiator cowl.
- Remove wiring from rear of Generator.
- Loosen connections for Generator from top and bottom and remove
Generator.
13-31
- Remove tensioner for ribbed belt from

bracket.
- Remove pulley from power steering pump.
- Unbolt power steering pump, move clear to one

side and tie in place. Do not open hydraulic
connections.
- Remove intake pipe support -arrows-.
13-32
- Unbolt bracket for Generator, steering pump and viscous fan -bolts 1 to
6-.
13-33
Installing

- Install bolts -1 to 6- with locking fluid "D 000 600" and tighten bolts
diagonally.
1, 2 - Bolt M10 x 85
3 to 6 - Bolt M10 x 45
- To help install Generator knock back bushing on bottom securing bolt
slightly.
- Remove viscous fan Page 13-21 .
- After connecting battery, enter anti-theft code for radio.
Radio operating instructions
- Close windows fully using window switches.
13-34
- Actuate all window switches again for at least

one second in the "close" direction to activate
the automatic open/close function.
- Set clock to correct time.
Tightening torques
Component Nm
Bracket for Generator, power steering
pump and viscous fan to cylinder block
52
1)
Support for intake manifold

to intake manifold 20
to bracket 20
Power steering pump to bracket 23
Pulley to coolant pump 23
Generator at bracket
M8 23
M10 46
Ribbed belt tensioner to bracket
23
Viscous fan to bearing 45
1) Install with locking fluid D 000 600 A2
13-35
Toothed belt drive
Note:

before removing the toothed belt. If the belt rotates
in the wrong direction when it is reinstalled, belt
breakage may result.
1 - Toothed belt guard - lower

To remove, unbolt vibration damper
2 - 10 Nm
Apply D 000 600 when installing
3 - Toothed belt guard - center
Unbolt tensioner before removing center
section of toothed belt guard
13-36
4 - Toothed belt guard - top

When installing, engage carefully in center
toothed belt guard
5 - Toothed belt
Mark direction of rotation with chalk or felt
pen before removing.
Check for wear
Removing Page 13-40
Install (adjust valve timing) Page 13-44
6 - Idler roller
7 - 27 Nm
8 - 65 Nm
Counter hold with 3036 to loosen and
tighten
13-37
9 - Camshaft sprocket
For exhaust camshaft
Take off toothed belt before removing and
installing Page 13-40
Installation position Fig. 1, Page
13-39
10 - Tensioner
11 - Washer
12 - Tensioner for toothed belt
13 - O-ring
Always replace
Lightly coat with coolant G 012 A8 D before
installing
14 - Coolant pump
13-38
15 - 15 Nm
16 - Crankshaft sprocket
Contact surface between sprocket and
crankshaft must be free of oil.
Can only be installed in one position.
17 - 90 Nm + 1/ turn (90 ) further
4
Always replace
Do not use oil
Counter hold with 3415 to loosen and
tighten
Fasten counterhold 3415 Fig. 2,
Page 13-39
18 - 15 Nm
19 - 25 Nm
13-39
Fig. 1 Location of camshaft sprocket

The narrow web of the camshaft sprocket faces outward -arrows- and
the marking for TDC of cylinder 1 is visible from front.
Fig. 2 Removing and installing toothed belt crankshaft

- Use counter-hold tool 3415 to loosen and tighten the central bolt.
13-40
Socket head fastener T10092
Pin T40011
13-41
Removing
Engine in vehicle.

Page 13-1 .
- Remove engine cover -arrows-.

- Remove ribbed belt and tensioner for ribbed belt Page 13-18 .
Allen key -2-.
- Remove viscous fan from mounting.
- Remove upper toothed belt guard.
13-42
- Mark direction of rotation of belt with chalk or felt

pen.
- Set crankshaft to markings for TDC of No. 1 cylinder by turning central

bolt on crankshaft sprocket in direction of rotation -arrows-.
- Unbolt vibration damper.
13-43
- Unbolt lower and center section of toothed belt guard -arrows-.
- Attach socket head fastener T10092 into the tensioner for toothed belt.
- Only tension pressure piston of tensioner until pressure piston is
secured with pin T40011.
- Take off toothed belt.
13-44
Installing (adjusting valve timing)
Note:
The position of the toothed belt must be set as

described below, even after repairs in which the
belt is only taken off the camshaft sprocket.
When turning the camshaft, the crankshaft must

not be at TDC at any cylinder. There is a
danger of damage to valves/piston crown.
- Align marking on camshaft sprocket with marking at cylinder head

cover.
- Place toothed belt on crankshaft sprocket (observe direction of
rotation).
- Install toothed belt guard - lower part.
- Secure vibration damper/belt pulley with one bolt (note installation
arrangement).
- Set crankshaft to TDC for cylinder No. 1.
- Install toothed belt onto coolant pump, then tensioning roller, and finally
camshaft sprocket.
13-45
- Unscrew socket head fastener T10092.

- Pull out pin T40011 from tensioner.
The pressure piston of the tensioner for the toothed belt loosens.
- Turn crankshaft two full turns in direction of rotation (by turning central
bolt on crankshaft sprocket) and check that camshaft and crankshaft
marks align with their reference points.
- Install vibration damper/belt pulley.
- Install toothed belt guard (center and top sections).
- Install viscous fan Page 13-21 .
- Install ribbed belt and tensioner for ribbed belt Page 13-20 .
13-46
Tightening torques
Component Nm
Lower section of toothed belt guard to
cylinder block
10 1)
Center section of toothed belt guard
to cylinder block
10 1)
Vibration damper/belt pulley to
crankshaft
10 + 90
2)3)
Ribbed belt tensioner to bracket
23
1) Install with locking fluid D 000 600 A2
2) Replace bolts
3) 90 corresponds to a quarter turn
13-1

assembling
3369 support tool
1 - Bolts
45 Nm (33 ft lb)
2 - Bolts
45 Nm (33 ft lb)
3 - Bolts
10 Nm (7 ft lb)
4 - Bolts
10 Nm (7 ft lb)
5 - Bore
For 3369 support tool
6 - Lock carrier bore
7 - Fender bore
13-2
- Remove front bumper.
- Remove 3 quick-release screws on front of noise

insulation panel.
- Unbolt air guide between lock carrier and air
cleaner at lock carrier.
- If installed, remove retaining clamps for wiring
harness on left side of radiator frame.
- Remove bolt -2- and install 3369 support tool.
- Install 3369 support tool into left bore -5-.
- Remove bolts -4- and pull lock carrier out to
stop.
- To secure lock carrier, install appropriate M6
bolts into rear bored holes of lock carrier -6- and
fender -7-.
13-3
- After installing lock carrier, check wiring for

proper routing near coolant fan.
Special tools Page 1 of 2
13-1
Special tools
The following special tools and test equipment are
required for these operations:
3204 Drift
3242 Crankshaft holder
3243 Camshaft holder tool
20-10 Kukko 2-arm puller
3203 Seal remover
3202 Retractor
3265 Seal installer
10-221 Extractor
13-2
2003/3 Seal installer

21/2 Kukko extractor
14.5 - 18.5mm
3264 Adjusting driver
3308 RPM sensor
adjusting device
VW 387 Dial gauge holder
Cylinder block, crankshaft and flywheel, servicing Page 1 of 33
13-4
Cylinder block, crankshaft and

flywheel, servicing
Notes:
Always replace seals and O-rings.
The engine speed sensor is installed in the
transmission bellhousing with a spacer washer
underneath.
1 - Main bearing cap bolts
Always replace
60 Nm (44 ft lb) + additional 180 (1/2 turn)
2 - Main bearing caps
Always replace bolts
Marking -1- on oil pump side
Checking bearing clearance page 13-25
3 - Connecting rod bearing bolts
Always replace
30 Nm (22 ft lb) + additional 90 (1/4 turn)
When measuring radial clearance, tighten
to 20 Nm (15 ft lb), but do not turn further
13-5
4 - Connecting rod bearings

Do not interchange used bearing shells
Connecting rods, connecting rod bearings
page13-33
5 - Piston rings
Checking page 13-29
6 - Pistons
Checking page 13-29
7 - Crankshaft
Checking page 13-25
Chain gear for oil pump, removing and
installing page 17-29
For vehicles with automatic transmission,
always install bushing as pilot for converter
Remove bushing using KUKKO 21/2 and
22/1
8 - Oil passage with seal
Always replace seal
9 - Sealing flange, front
10 - Bolt
10 Nm (7 ft lb)
11 - Collar bolt
30 Nm (22 ft lb)
13-6
12 - Thrust washer
Measuring crankshaft axial clearance
page 13-25
Only on 4th crankshaft bearing
13 - Special bolt (12-sided)
Always replace
Driveplate: 60 Nm (44 ft lb) + additional
90 (1/4 turn)
Dual-mass flywheel: 60 Nm (44 ft lb) +
additional 180 (1/2 turn)
14 - Dual-mass flywheel or driveplate
Needle bearing, removing and installing
page 13-21
15 - Crankshaft bearing
Axial and radial clearance, checking
page 13-25
16 - Bolt
10 Nm (7 ft lb)
17 - Oil jet
To cool pistons
18 - Seal for rear flange
Replacing page 13-18
13-7
19 - Bolt
10 Nm (7 ft lb)
20 - Bolt
25 Nm (18 ft lb)
Install hand-tight before fully tightening
21 - Cylinder block
13-8
Lock carrier in service position page 13-1
CAUTION!

on the pulley.
Removing
- Remove engine cover (arrows).
13-9
- Counterhold pulley for viscous fan using 3212 spanner wrench and
remove viscous fan using 3312 open-end spanner (left thread).
- Carefully lift out viscous fan.
Note:
Observe previously marked direction of rotation of belt and that it is

- To loosen ribbed belt, turn tensioner clockwise using 17 mm box

wrench until two holes are aligned (arrows). Counterhold in position
using 3204 drift.
- Remove ribbed belt.
13-10
Installing
- First install ribbed belt onto crankshaft pulley and idler wheel. Push belt
onto tensioning roller last.
Note:
Observe previously marked direction of rotation of belt and that it is

Routing of ribbed belt:
D1 - without air conditioning

D2 - with air conditioning
- Remove 3204 drift.
- Install engine cover.
Tightening torque for viscous fan Tightening

torque
1331 torque wrench and 3312 open-end spanner 37 Nm (27 ft lb)
1331 torque wrench without 3312 open-end 70 Nm (52 ft lb)
spanner
13-11

installing
Ribbed belt, removing and installing page 13-

8.
Note:
To remove the vibration damper, it is not

necessary to remove the center bolt.
- When installing, make sure notches (arrows) in vibration damper are

aligned with locating lugs on toothed belt sprocket.
Tightening torque (vibration damper to crankshaft): 20 Nm (15 ft lb)
13-12
Removing
- Remove engine cover.

Ribbed belt, removing and installing page 13-8 .
- Unclip toothed belt guard on both sides and remove.
13-13
- Turn crankshaft at central bolt of toothed belt gear in direction of

engine rotation to cyl. 1 TDC. Timing marks -A- and -B- must be
aligned.
- Check position of camshafts. Large holes (arrow) of securing plates on

camshaft sprockets must face toward inside and align.
If not, turn crankshaft one revolution further.
- Remove sealing plug from left-side of cylinder block.
- Top Dead Center (TDC) mark on crankshaft must be visible or be felt
behind bore of removed sealing plug.
WARNING!
DO NOT turn crankshaft while checking for TDC mark. Personal

injury may result.
13-14
- Install 3242 crankshaft holder into sealing plug opening.

- Remove tensioner for ribbed belt.
- Remove center and right toothed belt guards.
CAUTION!
Before removing ribbed belt, note direction of rotation with chalk or

felt-tip marker. Reversing the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt, make sure it is
Notes:
The toothed belt tensioner is oil dampened. Compress it by slowly
applying constant pressure.
Use spring clamp from 2024A.
- Using 8 mm hex wrench, turn toothed belt tensioning roller -1- counter-
clockwise, opposite direction shown (arrow), until tensioning lever -2-
compresses tensioner -3- so that spring clamp (2 mm dia.) can be
inserted into bore and lifter.
13-15
- Insert pin and release tension.
- Remove vibration damper page 13-11 .
- Remove idler wheel for ribbed belt (arrows).

- Remove toothed belt.
Installing
- Install 3391 camshaft locator bar onto camshaft locking plates.

- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove 3391 camshaft locator bar.
13-16
- Remove both camshaft sprockets using T40001 special tool.

- Reinstall both camshaft sprockets together with locking plates and
hand-tighten.
Note:
The camshaft sprockets should be loose enough on the cone to be

turned, but not so loose as to be tipped.
- Install toothed belt on all sprockets as shown in illustration.

- Install 3391 camshaft locator bar.
13-17
- Using 8 mm hex wrench, turn toothed belt tensioner roller -1- counter-
clockwise, opposite direction shown (arrow) until tensioning lever -2-
compresses tensioner -3- so that spring clamp can be removed and
then remove clamp.
- Before starting engine, pre-load timing tensioning roller as follows:
- Using a torque wrench with 8 mm hex bit, apply tension to toothed
belt clockwise in direction shown (arrow) until a torque of 15 Nm is
attained. This ensures tensioner has expanded completely and is
properly engaging toothed belt.
Component Tightening torque

Toothed belt sprocket to camshaft 55 (41 ft lb)
Idler wheel 45 (33 ft lb)
Toothed belt tensioning roller 20 (15 ft lb)
Belt pulley to crankshaft 20 (15 ft lb)
Toothed belt tensioner 10 (7 ft lb)
Center bolt 1) to crankshaft 200 (148 ft lb) + 180 2)
1) Always replace the center bolt.
2) Two turns of 90 are permissible.
13-18
Crankshaft seal, replacing
Toothed belt side
Ribbed belt, removing and installing page 13-

8.
Toothed belt, removing and installing page 13-

12 .
- Remove sealing plug from left-side of cylinder

block.
- Turn crankshaft to TDC for cylinder 3. The TDC

mark on crankshaft must be visible or felt behind
bore for sealing plug.
- Install 3242 crankshaft holder in bore to secure crankshaft.
13-19
- Remove crankshaft/toothed belt gear.
- Unscrew inner part of 3203 seal puller two turns

(approx. 3 mm) and secure using knurled bolt.
- Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
Installing
- Place 3202/1 guide sleeve on crankshaft pin.

- Slide dry oil seal over guide sleeve.
- Press in oil seal to stop using 3265 seal installer.
The rest of the installation follows is the reverse of removal.
13-20
Dual-mass flywheel
Notes:
Only replace oil seal with sealing flange.
Drain coolant before removing sealing flange

page 19-11 .
If sealing flange is not available, proceed as

follows:
- Remove clutch and dual-mass flywheel or

driveplate.
- Pry out seal using 10-221 extractor.

- Clean running and sealing surfaces.
- Push seal onto crankshaft using assembly aid.
Notes:
Do not lubricate sealing lip or outer edge of seal before pressing in.
The assembly aid is supplied with the seal.
- Press in seal up to stop using 2003/3 seal installer and bolts for dual-
mass flywheel or driveplate.
13-21
Dual-mass flywheel pilot needle bearing,

- Remove pilot needle bearing using puller -A- (e.g. KUKKO 21/2 and
KUKKO 22/1).
- Install bearing using 3264 bearing driver.
13-22
Dual-mass flywheel or driveplate,

removing and installing, installation
dimensions
Dual-mass flywheel
- With crankshaft at Top Dead Center (TDC), install 3242 crankshaft

holder.
- Mark position of dual-mass flywheel and engine housing (arrows).
- Remove bolts and replace.
Note:
A pilot needle bearing is in the dual-mass flywheel and must be inserted

when dual-mass flywheel is replaced.

Dual-mass flywheel to crankshaft 60 Nm (44 ft lb) + 180
Clutch to dual-mass flywheel 20 Nm (15 ft lb)
Note:
Always replace dual-mass flywheel mounting bolts.
13-23
Driveplate
- Hold crankshaft in position using 3242

crankshaft holder page 13-12 .
- Mark hole pattern of driveplate, shim -1- and

washer -2- to crankshaft.
- Mark positions of shim -1- and washer -2-

(behind driveplate).
- Install driveplate with washer -2- (Part No. 035 105 303 A) and shim -1-
3.0 mm (Part No. 054 105 301) or 4.0 mm (Part No. 054 105 202).
CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.
Notes:
Short engines and exchange engines are supplied without a bushing
in the crankshaft. Always install a new bushing before installing the
driveplate.
Remove bushing using 21/1 Kukko puller and 21/2 Kukko support.
Always replace driveplate mounting bolts.

Driveplate to crankshaft 30 Nm (22 ft lb) + 90
13-24
- Measure distance -a- at three places and calculate average.

Distance -a-: approx. 12.3 mm.
- If necessary, install different shim.
Note:
Before installing the engine, make sure the engine to transmission

centering sleeves are installed in the engine flange.
13-25
Crankshaft axial and radial clearance,

measuring
Axial clearance
CAUTION!
Bearing shells must be reinstalled in their

original location and orientation. Always label
the bearing shells according to their installed
position before removing. Never interchange
used bearing shells.
- Attach dial indicator together with VW387 dial indicator holder to oil
pump and set indicator against crankshaft counterweight.
- Press crankshaft against dial indicator by hand and set indicator to
zero.
- Press crankshaft away from dial indicator.
- Read gauge.
Clearance when new Wear limit

0.07-0.23 mm (0.0028-0.0091 in.) 0.25 mm (0.0098 in.)
13-26
Radial clearance
- Measure radial clearance using Plastigage .
- Read clearance.

0.018-0.045 mm (0.0007- 0.10 mm (0.0039
0.0018 in.) in.)
CAUTION!
DO NOT turn the crankshaft or allow it to

rotate while measuring with Plastigage in
place.
13-27
Crankshaft bearing cap, installing
Bearing -1- is installed on the oil pump side of the cylinder block, and
bearing -4- on the dual-mass flywheel side of the cylinder block.
13-28
Crankshaft dimensions
Engine codes AHA, ATQ
Reconditioning dimension Crankshaft journal diameter mm (in.) Connecting rod journal diameter mm (in.)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
Standard (nominal dimension) 65.00 (2.559) 54.00 (2.126)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
1st undersize (nominal dimension) 64.75 (2.549) 53.75 (2.116)
2nd undersize (nominal dimension) 64.50 (2.539) 53.50 (2.106)
3rd undersize (nominal dimension) 64.25 (2.530) 53.25 (2.096)
13-29
Pistons and piston rings
Pistons
Installation position: arrow on piston crown must point in driving direction.
- Mark cylinder number on piston crown using waterproof felt pen.
CAUTION!
DO NOT scratch or scribe on piston crown. The surface has a

coating that must not be damaged.
Checking piston diameter
- Measure pistons approx. 10 mm (3/8 in.) from bottom edge at right

angle (90 ) to piston pin.
Deviation from nominal size: 0.04 mm (0.0016 in.).
13-30
Piston and cylinder bore dimensions
Reconditioning Piston diameter

dimension
Basic dimension 82.48 mm (3.247
in.)
1st oversize 82.74 mm (3.257
in.)
Checking piston ring side clearance

0.02-0.08 mm (0.0008-0.0031 in.) 0.10 mm (0.004 in.)
13-31
Checking piston ring end gap
- Insert ring at right angle from top and slide down into lower cylinder
opening until approx. 15 mm from lower edge of cylinder.
Piston ring End gap, new mm. (in.) Wear limit mm.
(in.)
1 0.35-0.50 mm (0.014-0.020 1.0 mm (0.039 in.)
(compression) in.)
2 0.50-0.70 mm (0.020-0.028 1.4 mm (0.043 in.)
(compression) in.)
3 (oil scraper) 0.25-0.50 mm (0.010-0.020 0.8 mm (0.031 in.)
in.)
13-32
Cylinder bore, checking
- Measure at three locations diagonally in crosswise direction -A- and

lengthwise direction -B-.
Inner bore gauge: 50-100 mm (1.96-3.94 in.)
Deviation from nominal size: max. 0.08mm (0.0031 in.)
Piston and cylinder bore dimensions
Reconditioning Piston diameter Cylinder bore

dimension diameter
Basic dimension 82.48 mm (3.2472 82.51 mm (3.2484
in.) in.)
1st oversize 82.74 mm (3.2575 82.76 mm (3.2578
in.) in.)
Note:
Replacement pistons are only available in the basic dimension.
CAUTION!
DO NOT measure cylinder bore dimensions while the cylinder block

is mounted on the engine stand. The cylinder block is stressed and
deformed by its own weight under these conditions and the
measurements will not be accurate.
13-33
Connecting rod and connecting rod

bearings, checking clearance
Notes:
Replace the connecting rods only as a set.
Do not interchange connecting rod bearings.
- Mark connecting rod bearing caps with light center punch marks before
removing.
Checking radial clearance
- Remove connecting rod bearing caps. Clean bearing shells and

journals.
- Place Plastigage over entire width of bearing journal or bearing cap.
- Install connecting rod bearing cap and tighten to 20 Nm (15 ft lb).
CAUTION!
DO NOT turn the crankshaft or allow it to rotate while measuring with

Plastigage in place.
- Remove connecting rod bearing cap again.

- Compare width of Plastigage with calibrated scale.
13-34

0.015-0.062 mm (0.0006- 0.12 mm (0.0047
0.0024 in.) in.)
- Always replace connecting rod bolts.
Toothed drive belt, assembly Page 1 of 2
13-4
Toothed drive belt, assembly

1 - Bolt
70 Nm (52 ft lb)
2 - Locking plate
Side with inscribed lettering always faces
camshaft
Removing page 13-12
Tighten camshaft sprockets after toothed
belt tension is adjusted
CAUTION!
Camshaft holder 3243 must be installed

before attaching camshaft sprockets.
Do not tighten the camshaft sprockets until
after toothed belt tension has been adjusted.
Toothed drive belt, assembly Page 2 of 2
13-5
4 - Toothed belt tensioner

45 Nm (33 ft lb)
5 - Toothed belt
6 - Toothed belt cover
7 - 10 Nm (7 ft lb)
8 - 25 Nm (18 ft lb)
Cylinder block, crankshaft and flywheel, disassembly and assembly Page 1 of 26
13-14

flywheel, disassembly and
assembly
Note:
Replace all gaskets and seals.
1 - Thrust washers
Measuring axial clearance of crankshaft
Page 13-21
Thrust washer only fitted on 4th crankshaft
bearing
2 - Special bolt (double hex)
Replace
Dual-mass flywheel: 60 Nm + 180 (1/2
turn)
13-15
3 - Dual-mass flywheel
Removing and installing needle bearing
Page 13-35
4 - Crankshaft bearing
Checking axial and radial clearance
Page 13-21
5 - Bolt, tightening torque 10 Nm
6 - Oil spray jet
For piston cooling
7 - Oil seal for rear sealing flange
Replacing Page 13-23
13-16

9 - Rear sealing flange
10 - Gasket
Screw in bolts on left and right sides finger-
tight before tightening bolts on main
bearing caps.
12 - Cylinder block
13 - Gasket
13-17
14 - Collar bolt, tightening torque 30 Nm

Apply Loctite when installing
16 - Front sealing flange
17 - Expansion pins
18 - Crankshaft
Checking Page 13-21
19 - Chain sprocket for oil pump
20 - Pistons
Checking Page 13-36
13-18
21 - Piston rings
Checking Page 13-36
22 - Circlip for piston pin
23 - Piston pin
24 - Connecting rod
Mark cylinder number and installation
position of matching connecting rods and
bearing caps before removing
Installation position: wider, slightly convex
machined surfaces on the same side
25 - Connecting rod bearing
Do not interchange used bearing shells.
Connecting rods, connecting rod bearings
Page 13-39
13-19
26 - Connecting rod bearing bolts

Always replace
Tightening torque: 30 Nm + 90 (1/4turn)
When measuring radial clearance, tighten

to 20 Nm but do not turn further.
27 - Main bearing cap
Marking -1- on oil pump side
Replace bolts for main bearing caps
Watch position of dowel sleeves
Checking bearing clearance Page 13-21
28 - Bolts for main bearing caps
Always replace
Tightening torque Page 13-20
Tightening sequence Page 13-20
13-20
Crankshaft bearing caps, installing
- Bearing -1- is at the toothed belt end; bearing -4-

is at the flywheel end.
Tightening sequence:
- Stage 1 Tighten all bolts in the sequence shown (1 - 16) to 30 Nm.

- Stage 2 Tighten all bolts in the sequence shown (1 - 16) to 60 Nm.
- Stage 3 Using a fixed wrench, turn all bolts in the sequence shown (1 -
16) 90 further.
- Tighten bolts -A- to 25 Nm.
13-21

measuring
Axial clearance
Note:
Do not interchange used bearings.
- Attach dial gauge with universal dial gauge bracket VW 387 to oil pump
and bring it into contact with crank web.
- Press crankshaft against dial gauge by hand and set gauge to -0-.
- Press crankshaft away from dial gauge.
- Note reading:

0.090 ... 0.251 mm 0.28 mm
13-22
Radial clearance
Measure radial clearance with Plastigage .
- Read value:

0.018 ... 0.045 mm 0.10 mm
13-23
Crankshaft oil seals, replacing
A - Toothed belt end
- Remove toothed belt Page 13-4 .
- Remove toothed belt sprocket from crankshaft
- Pull out oil seal with oil seal extractor 3203.

- Clean contact surface and sealing surface.
Note:
Do not lubricate sealing lip or outer circumference of seal before pressing

in.
- Push on seal using fitting sleeve 3202/1.
- Press in seal until flush using fitting sleeve 3265 and central bolt.
13-24
B - Flywheel end
Note:
Replace oil seal together with sealing flange.
Vehicles with manual transmission
- Drain off coolant Page 19-19 .
- Remove transmission.
Repair Manual, 6 Spd. Manual Transmission

01E, Repair Group 34
- Remove clutch.
- With crankshaft at TDC, screw in clamping bolt 3242.

- Mark position of flywheel relative to engine -arrows-.
- Remove dual-mass flywheel.
- Remove sealing flange.
13-25
Installing
- Install sealing flange.
- Install dual-mass flywheel with new bolts.
Note:
Always replace securing bolts for dual-mass

flywheel.
- Install clutch.

Tightening torques
Dual-mass flywheel to 60 Nm + 180
crankshaft
Clutch to dual-mass flywheel 20 Nm
13-26
Vehicles with automatic transmission

- Drain off coolant Page 19-19 .
Note:

camshaft sprockets must align opposite one another on inside. If this is
not the case, turn crankshaft one revolution further.
- The TDC drilling in crankshaft must be visible (or able to be felt) in line
with sealing plug hole.
CAUTION!
Injury risk - do not turn engine while feeling for TDC drilling.
13-27
tighten.
- Mark positions of holes in drive plate, shim -1- and washer -2- in
relation to crankshaft.
- Mark positions of shim -1- in front of drive plate and washer -2- behind
drive plate.
Installing
- Install drive plate with washer -2- and shim -1- (3.0 mm or 4.0 mm).
Note:
Short engines and exchange engines are supplied without bush in
crankshaft. On vehicles with automatic transmission, always knock in
new bush before installing drive plate.
Always replace drive plate securing bolts.
13-28
Tightening torques
Drive plate to crankshaft 60 Nm + 90
Note:
Always replace securing bolts for drive plate.
- Measure distance -a- at three points and calculate average value.

Distance -a- = approx. 29.9 mm.
- Install a different shim if necessary.
Note:
Before installing the transmission, check that the dowel sleeves for
locating engine/transmission are fitted in the engine flange.
- Install transmission.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
13-29
Dual-mass flywheel / drive plate,

installation dimensions, removing and
installing
A - Flywheel
Removing

- Remove clutch.
- With crankshaft at TDC, screw in clamping bolt 3242.

- Mark position of flywheel relative to engine -arrows-.
- Remove bolts (bolts must be replaced).
13-30
Note:
The needle bearing is located in the flywheel and

must be pressed in if a new flywheel is installed
Page 13-35 .
Installing
- Install dual-mass flywheel.
Note:
Always replace flywheel securing bolts.
- Install clutch.


13-31
Tightening torques
Dual-mass flywheel to 60 Nm + 180
crankshaft
Clutch to dual-mass flywheel 20 Nm
B - Drive plate
Removing

Note:

13-32
- TDC drilling in crankshaft must be visible (or

able to be felt) in line with sealing plug hole.
CAUTION!
Injury risk - do not turn engine while feeling

for TDC drilling.
tighten.
- Mark positions of holes in drive plate, shim -1- and washer -2- in
relation to crankshaft.
- Mark positions of shim -1- in front of drive plate and washer -2- behind
drive plate.
13-33
Installing
- Install drive plate with washer -2- and shim -1- (3.0 mm or 4.0 mm).
Note:
Short engines and exchange engines are supplied without bush in
crankshaft. On vehicles with automatic transmission, always knock in
new bush before installing drive plate.
Always replace drive plate securing bolts.
Tightening torques
Drive plate to crankshaft 60 Nm + 90
13-34

Distance -a- = approx. 12.3 mm.
- Install a different shim if necessary.
Note:
Before installing the transmission, check that the dowel sleeves for
locating engine/transmission are fitted in the engine flange.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
13-35
Needle bearing in dual-mass flywheel,

- Pull out with puller, such as KUKKO 21/2 and KUKKO 22-1.
- Drive in with drift 3264.
13-36
Pistons and piston rings, installing
Pistons
Position: arrow on piston crown must always face in direction of travel.
- Mark cylinder number on piston crown with waterproof felt pen.
Note:
Do not use a center-punch or similar, as pistons have a special coating.
Checking piston diameter
- Measure pistons approx. 10 mm from bottom of skirt, at 90 to piston

pin axis.
Difference between actual and nominal diameter: not more than
0.04 mm.
13-37
Ring-to-groove clearance

0.02 ... 0.08 mm 0.10 mm
Checking piston ring gap
- Push ring in squarely to a position approx. 15 mm from bottom end of

cylinder.
Piston ring Gap when new Wear limit

1 0.35 ... 0.50 mm 1.0 mm
2 0.50 ... 0.70 mm 1.4 mm
3 0.25 ... 0.50 mm 0.8 mm
13-38
Cylinder bores, checking
- Measure bores at three points in both directions: across engine -A- and
in line with crankshaft -B-.
Use internal dial gauge 50 to 100 mm.
Difference between actual and nominal diameter: not more than
0.08 mm.
Piston and cylinder dimensions
Honing dimension Piston dia. Cyl. bore dia.

Basic dimension 80.95 mm 81.01 mm
Note:
Replacement pistons are only available with basic dimension.
13-39
Connecting rods and connecting rod

bearings, installing
Note:
Only replace complete sets of connecting

rods
- Before removing, mark positions of connecting rod bearing caps with a

felt pen or similar.
- Remove connecting rod bearing cap. Clean bearing cap and bearing
journal.
- Place a length of Plastigage corresponding to width of bearing on
bearing journal or bearing shell.
- Install connecting rod bearing cap and tighten to 20 Nm. Do not rotate
crankshaft.
- Remove connecting rod bearing cap again.
- Compare width of Plastigage with calibrated scale.

0.015 ... 0.062 mm 0.12 mm
- Install new connecting rod bearing bolts.
Cylinder block, crankshaft and flywheel, component layout Page 1 of 32
13-6

flywheel, component layout
Note:
Always replace gaskets and seals.

Always replace
Tightening torque: 60 Nm (44 ft lb) plus
1/2-turn (180 )
2 - Main bearing cap
ID: "1" on side facing oil pump
Always replace bolts
Checking bearing clearance page 13-21
3 - Connecting rod bearing cap bolts
Always replace
1/4-turn (90 )
Tighten to 20 Nm (15 ft lb) for measuring
radial clearance, but do NOT tighten further
4 - Connecting rod bearing shells
Never interchange used connecting rod
bearing shells
Checking connecting rods and bearings

page 13-31
13-7
5 - Piston rings
Checking page 13-25
6 - Piston
Checking page 13-26
7 - Crankshaft
Checking page 13-21
Dimensions page 13-24
8 - Oil pump
Check drive gear on crankshaft when
installing
Removing Repair Group 17
9 - 10 Nm (7 ft lb)
10 - Thrust washers
Installed only at 4th crankshaft main
bearing
Checking crankshaft axial clearance
page 13-21
11 - Bolt
Automatic trans. (drive plate)
Always replace
1/4-turn (90 )
Manual trans. (flywheel)

Always replace
1/2-turn (180 )
13-8
12 - Dual mass flywheel or drive plate

Removing and installing, installation
dimensions page 13-17
Removing and installing pilot needle
bearing page 13-16
Adjusting engine speed (RPM) sensor
bracket -G28- page 13-20
13 - Main bearing shell
Checking radial clearance page 13-21
14 - Seal
15 - 10 Nm (7 ft lb)
16 - 25 Nm (18 ft lb)
Thread bolts in hand-tight before tightening
crankshaft main bearing caps
17 - Cylinder block
13-9
CAUTION!
Mark the direction of belt travel before

removing, using a crayon or marker.
Reinstalling a used belt in the opposite
direction could damage the belt.
Removing
- Remove engine and ribbed-belt guard.
- Loosen ribbed-belt tensioner using 17 mm

wrench and secure with locking drift 3204.
- Remove ribbed belt.
Installing
- Install ribbed belt over the crankshaft belt pulley

and guide pulley first, and then push it onto the
tensioning pulley.
- Remove locking drift 3204.
- Install engine and ribbed belt guard.
Routing of ribbed belt drive -D-
D1 - Without air conditioner

D2 - With air conditioner
13-10

installing
Removing
Removing ribbed belt page 13-9 .
Note:
The center bolt does not have to be loosened to

remove the vibration damper.
Installing
- When installing, make sure that notch (arrow) in vibration damper is

aligned with locking lug on toothed belt sprocket.
13-11
Removing
CAUTION!
Mark the direction of belt travel before

removing, using a crayon or marker.
Reinstalling a used belt in the opposite
direction could damage the belt.
- Remove ribbed belt page 13-9 .
- Unclip toothed belt guard on both sides.
- Crank engine by hand to Top Dead Center (TDC) position.

- Check camshaft position. Large holes in camshaft sprocket locking
plates must face toward each other. If not, turn crankshaft one more
revolution.
- Remove Crankshaft Position (CKP) sensor from left-hand side of
cylinder block.
The TDC hole in the crankshaft must be aligned with the hole for the
removed crankshaft position sensor (check by looking and feeling).
- Thread crankshaft holder 3242 into hole left by crankshaft position

sensor, and tighten slightly.
- Remove ribbed-belt tensioner.
13-12
- Remove left and right toothed-belt guards.
- Remove vibration damper page 13-10 .
- Remove lower toothed-belt guard.
- Loosen toothed-belt tensioning pulley, and

remove belt.
Installing
- Loosen right and left camshaft sprockets from tapered ends of

camshafts using puller (Kukko 20-10 or equivalent).
Note:
The arms of the puller must engage on the rear hub of the sprocket.
- Install toothed belt over both camshaft sprockets first, then over
remaining sprockets, and over tensioning roller last.
- Install camshaft holder 3243.
Note:
The camshaft sprockets must be loose enough on the tapered ends of the
shafts so that the camshafts can still be turned, but tight enough that the
sprockets do not tilt out of alignment.
- Adjust belt tension page 13-13 .
13-13
Toothed belt, adjusting tension
- Adjust toothed belt tension by turning tensioning

roller to right and holding using 8 mm hex socket
wrench.
- Tighten tensioning roller center bolt with another

8 mm hex socket wrench.
- Check toothed belt tension between right camshaft sprocket and

coolant pump.
Holding toothed belt half way between camshaft sprocket and coolant
pump with thumb and index finger, it must be just possible to twist
toothed belt by 90 .
Tightening torque (tensioning roller): 45 Nm (33 ft lb)
Center crankshaft bolt: Always replace, using new double hex head (12-
pt.) cap screw grade 9.8

Toothed belt sprocket to camshaft 70 (52 ft lb)
Idler roller 25 (18 ft lb)
Toothed belt tensioner 45 (33 ft lb)
Belt cog to crankshaft 25 (18 ft lb)
Center bolt 1) to crankshaft 200 (148 ft lb) + 180 2)
1) Always replace the center bolt.
2) Two turns of 90 are permissible.
13-14
Crankshaft oil seals, replacing
Toothed belt end (front)
- Remove toothed belt page 13-11 .
- Remove toothed belt sprocket from

crankshaft.
- Remove oil seal using seal remover 3203.

Note:
Do not oil sealing lip or outer edge of seal before pressing in.
- Push oil seal over 3202/1 from retractor 3202.

- Press in oil seal flush with seal installer 3265 and center crankshaft
bolt.
13-15
Flywheel/drive plate end (rear)
CAUTION!
Always replace the seal with the flange, if

available. Drain engine coolant before
removing flange ( Repair Group 19).
Replace only seal as described below if oil
seal with flange is not available.
- Remove clutch and flywheel, or drive plate, as

necessary.
- Pry out oil seal with extractor 10-221.

Note:
Do not oil sealing lip or outer edge of seal before pressing in.
- Using assembly aid supplied with new oil seal, slide seal onto
crankshaft.
Assembly aid is supplied with oil seal
- Press in oil seal as far as possible using seal installer 2003/3 and
flywheel or drive plate mounting screws.
13-16
Flywheel pilot needle bearing, removing

and installing
- Remove bearing with puller assembly such as Kukko 21/2 and Kukko
22-1, as shown
- Install bearing with drift 3264.
13-17
Dual mass flywheel or drive plate,

Flywheel
- Install crankshaft holder 3242 with crankshaft at Top Dead Center

(TDC) position.
- Mark relationship between flywheel and engine cylinder block (arrows).
- Remove flywheel.
Note:
The needle roller bearing is in the flywheel and must be pressed in when
replacing the flywheel.
Tightening torque
Dual mass flywheel: 40 Nm (30 ft lb) plus 1/2-turn (180 )
13-18
Drive plate
- Hold crankshaft in position using crankshaft

holder 3242 page 13-11
- Mark bolt hole pattern of drive plate and washers -1- and -2- relative to
crankshaft. Mark position of shim in front and shim behind drive plate.
CAUTION!
Part numbers are listed for reference only. Always check with your
Parts department for the latest information.
- Install drive plate with 3.0 mm shim -1- (Part no. 054 105 301) or 4.0
mm shim -1- (Part no. 054 105 202), and spacer -2- (Part no. 035 105
303A).
Note:
Short blocks are supplied without a bushing in the crankshaft. For

vehicles with automatic transmission, tap the bushing into place before
installing the drive plate.
13-19
- Check clearance -a- between drive plate and cylinder block in three
places and calculate average value.
Dimension -a-:
Transmission 01V: 18.1-19.7 mm (0.713-0.776 in.)
- If necessary, install other shims to achieve correct clearance
dimension.
Tightening torque: 60 Nm (44 ft lb) plus 1/4-turn (90 )
Note:
Before installing the engine, make sure that the engine-to-transmission

dowel sleeves are installed in the cylinder block flange.
13-20
Engine speed (RPM) sensor mounting

bracket, adjusting
Note:
The crankshaft must be at TDC and locked in

position with crankshaft holder 3242 page 13-
11 .
- Remove heat shield for RPM sensor, and then

remove RPM sensor.
- Loosen bracket.
- Insert adjustment tool 3308 in place of sensor.

Adjustment tool must engage in flywheel ring gear.
- Tighten bracket securely.
- Install RPM sensor.
13-21

checking
Orientation of crankshaft bearing caps
CAUTION!
Bearing shells must be reinstalled in their original location and

orientation. Always label the bearing shells according to their
installed position before removing. NEVER interchange used bearing
shells.
Main bearing cap -1- is at the oil pump end (front).

Main bearing cap -4- is at the flywheel end (rear).
Checking axial clearance
- Install dial indicator with holder VW 387 on oil pump and set indicator
against crankshaft counterweight.
- Press crankshaft against dial indicator by hand.
- Set dial gauge to zero.
- Press crankshaft away from dial indicator and read gauge.
Specifications:
New: 0.07-0.23 mm (0.0027-0.0091 in.)
Wear limit: 0.25 mm (0.0098 in.)
13-22
Note:
Radial clearance is measured using Plastigage

.
Plastigage type Color Measuring range

PG-1 Green 0.025 - 0.076 mm
PR-1 Red 0.050 - 0.150 mm
- Remove crankshaft bearing cap.
- Clean bearing shell and crankshaft journal.
- Place Plastigage on crankshaft journal over entire width of bearing,

or in bearing shell (arrow).
- Install crankshaft bearing cap with bearing shell and new bolts.
- Tighten to 60 Nm (44 ft lb) plus1/2-turn 180 .
CAUTION!
Do NOT turn the crankshaft or allow it to rotate during the

measurement with Plastigage in place.
13-23
- Remove crankshaft bearing cap again.
- Compare width of Plastigage with measuring scale.

Specifications:
New: 0.018-0.045 mm (0.0007-0.0018 in.)
13-24
Reconditioning dimension Crankshaft journal Connecting rod journal
diameter - mm (in.) diameter - mm (in.)

Basic dimension (nominal) 65.00 (2.559) 54.00 (2.126)
1st undersize (nominal) 64.75 (2.549) 53.75 (2.116)
2nd undersize (nominal) 64.50 (2.539) 53.50 (2.106)
3rd undersize (nominal) 64.25 (2.530) 53.25 (2.096)
13-25
Pistons and piston rings, checking and

installing
Note:
Before removing the pistons, mark their

installation positions clearly on the piston crowns
(as shown in illustration 13-860) using a
waterproof felt-tipped pen.
Piston installed position
- Arrow marking must point toward oil pump (front).

- Mark position clearly on piston crown with waterproof felt pen.
CAUTION!
Do NOT scratch or scribe the piston surface. This surface has a

coating on it that must not be disturbed.
- Install piston using piston ring compressor.
13-26
Checking pistons
- Measure piston approx. 10 mm (0.39 in.) from bottom of skirt, at right

angle (90 ) to piston pin.
Maximum deviation from nominal dimension: 0.04 mm (0.0016 in.)
Checking and installing piston rings
"TOP" inscription must point toward piston crown
Inner chamfer on plain ring must point toward piston crown
Outer chamfer of stepped ring must point toward piston crown
13-27
- Remove and install piston rings using ring expander as shown.
- Check piston ring clearance in groove.

New: 0.02-0.08 mm (0.001-0.003 in.)
13-28
- Check piston ring gap.

- Push piston ring into lower end of cylinder at right angle until approx.
15 mm (0.59 in.) from bottom edge.
Piston ring End gap Wear limit

1 0.35 - 0.50 mm 1.0 mm
(0.014 - 0.020 in.) (0.039 in.)

2 0.50 - 0.70 mm 1.4 mm
(0.020 - 0.028 in.) (0.055 in.)

3 0.25 - 0.50 mm 0.8 mm
(0.010 - 0.020 in.) (0.032 in.)
13-29
Checking cylinder bore
1 - Approx. 10 mm from top
2 - Center
3 - Approx. 10 mm from bottom
A - Across cylinder block (perpendicular to

crankshaft)
B - In line with cylinder block (parallel to

crankshaft)
- Measure diagonally at three points in transverse direction -A- and in

longitudinal direction -B-.
Use internal dial gauge 50-100 mm (2-4 in.)
Maximum deviation from nominal dimension: 0.08 mm (0.0031 in.)
CAUTION!
DO NOT have the cylinder block mounted to the assembly stand

while measuring the cylinder bores. The block is deformed by its
own weight under these conditions and this stress will result in false
measurements that are not accurate after the tension has been
relieved.
13-30
Reconditioning Piston Cylinder

dimension bore
diameter
diameter
Basic dimension 82.48 mm 82.51 mm
(3.2484 in.)
(3.2472
in.)
1st oversize 82.74 mm 82.76 mm
(3.2583 in.)
(3.2575
in.)
2nd oversize 82.98 mm 83.01 mm
(3.2681 in.)
(3.2669
in.)
Note:
Only pistons of the "basic dimension" size are

available from the Parts Department.
13-31
Connecting rods and connecting rod

bearings, checking
Replace connecting rods only as a complete

set.
Always replace connecting rod bearing cap

bolts.
- Mark connecting rod bearing caps with light punch marks (arrow)
before removing.
- Remove connecting rod bearing caps.
- Clean bearing caps and journals.
- Place Plastigage over entire width of bearing journal or in bearing
shell.
- Re-install connecting rod bearing cap and tighten to 20 Nm (15 ft lb)
only; do NOT tighten further.
CAUTION!
Do NOT turn the crankshaft or allow it to rotate during the

measurement with Plastigage in place.
13-32
- Remove connecting rod bearing caps again.
- Compare width of Plastigage with measuring

scale.
Specifications:
0.015 to 0.062 mm (0.00059 to

New:
0.00244 in.)
0.12 mm (0.0047 in.)
Wear
limit:
Sealing flange and flywheel/drive plate, removing and installing Page 1 of 11
13-36
Sealing flange and

flywheel/drive plate, removing
and installing
Note:
Servicing clutch:

012/01W Front Wheel Drive, Repair Group 30
01A All Wheel Drive, Repair Group 30
1 - Oil seal
To remove, remove oil seal carrier, item -
15 -
Install using 10-203
Lightly oil lip of seal
2 - Woodruff key
Check for proper installation
3 - Connecting bolt
25 Nm (18 ft lb)
4 - Front oil seal flange
Before installing oil pan, spread sealant
AMV174 004 01 on joint between oil seal
flange and cylinder block.
13-37
5 - Gasket
Always replace
6 - Cylinder block
Crankshaft, removing and installing
Page 13-46
Pistons and connecting rods,
disassembling and assembling Page 13-
53
7 - Mounting bolt for dual-mass
flywheel/drive plate
Always replace
Tightening torque for dual-mass flywheel:
60 Nm (44 ft lb) + additional 1/2 turn (180
)
Tightening torque for drive plate (vehicles
with automatic transmission): 60 Nm (44 ft
lb) + additional 1/4 turn (90 )
8 - Dual-mass flywheel or drive plate
9 - Intermediate plate
Must fit on bushings
Do not damage or bend while performing
repairs
13-38
10 - Bolt
10 Nm (7 ft lb)
11 - Rear oil seal flange
With oil seal
Replace as complete unit
Lightly oil lip of seal
Before installing oil pan, spread sealant
AMV 174 004 01 on joint between oil seal
flange and cylinder block
12 - Oil seal
13 - Intermediate shaft
Axial play, max: 0.25 mm (0.010 in.)
14 - O-ring
Always replace
15 - Oil seal carrier for intermediate shaft
13-39
Crankshaft oil seal (toothed belt side),

replacing
Engine installed
2085 seal puller
3083 arbor
3099 spur belt spreading
Removing
- Remove ribbed belt and ribbed belt tensioner

Page 13-15 .
- Remove mounting bracket for torque arm

Page 17-2 , item - 5 -.
- Remove crankshaft toothed belt gear. Secure toothed belt gear using
3099 spur belt spreading.
Note:
3415 special tool can also be used.
13-40
- Before attaching seal puller, insert socket head cap bolt from 3083
arbor into crankshaft to stop.
- Unscrew inner part of 2085 seal puller two turns (approx. 3 mm 0.118
in.) and secure using knurled bolt.
- Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
13-41
Installing
- Lightly oil lip of oil seal.
- Place guide sleeve from 3083 arbor on crankshaft.

- Slide oil seal over guide sleeve.
- Press in oil seal to stop together with pressure bushing and bolt from
3083 arbor.
- Replace bolt for toothed belt gear.
- Install toothed belt gear for crankshaft and secure using 3099 spur belt
spreading.
Note:
Contact surface between toothed belt gear and crankshaft must be
free of oil.
Do not grease crankshaft bolt for toothed belt gear.
- Install toothed belt (adjust valve timing) Page 13-32 .
13-42
- Place torque arm on rubber buffer for torque arm

and tighten bolts to 25 Nm (18 ft lb).
- Install ribbed belt and ribbed belt tensioner

Page 13-15 .
Note:
When installing the ribbed belt, make sure it is

Tightening torque

Toothed belt gear to 90 Nm (66 ft lb) +
crankshaft 90 1)2)
1) Replace bolt.
2) 90 are equivalent to 1/4 turn.
13-43
Dual-mass flywheel/drive plate,

10-201 flywheel retainer
Dual-mass flywheel
- Relocate 10-201 flywheel retainer to loosen and tighten bolts.

- Mark installed position (flywheel to crankshaft) to reinstall in same
position.
- Always replace bolts.
Tightening torque

Dual-mass flywheel to crankshaft 60 Nm (44 ft lb) + 180 1)
13-44
Drive plate
Removing
- Relocate 10-201 flywheel retainer to loosen and tighten bolts.

- Mark drive plate to engine.
Installing
- Install drive plate with shim -2- and mounting washer -1-. Lug (arrow)
must point toward torque converter.
- Insert at least three used mounting bolts and tighten.
13-45
- Measure distance -a- at three places and calculate average.

Specification for Automatic Transmission 01V: 26-28 mm (1.024-1.102
in.).
If the specified value is exceeded:
- Remove drive plate and reinstall without shim -2-.

- Re-tighten bolts to 30 Nm (22 ft lb).
- Repeat measurement procedure.
If specified value is obtained:
- Replace bolts and tighten.
Tightening torque

Drive plate to crankshaft 60 Nm (44 ft lb) + 90 1)
Crankshaft, removing and installing Page 1 of 8
13-46
Crankshaft, removing and

installing
Note:
For engine disassembly and assembly, mount

engine to an assembly stand using VW540 holding
fixture.
1 - Main bearing shells 1, 2, 4 and 5

Install shell without lubrication groove in
main bearing cap
Install shell with lubrication groove in
cylinder block
Do not interchange used main bearing
shells (mark accordingly)
Always replace
To measure radial play in crankshaft,
tighten to 65 Nm (48 ft lb) but not any
further
3 - Main bearing caps
Bearing cap 1: belt pulley side
Retaining tabs for cylinder block/bearing
cap must overlap
13-47
4 - Main bearing shell 3

Install shell without lubrication groove in
main bearing cap
Install shell with lubrication groove in
cylinder block
Do not interchange used main bearing
shells (mark accordingly)
5 - Thrust plates
For bearing cap, bearing 3
Check location point
6 - Sensor wheel
Always replace when bolts are removed
For engine speed (RPM) sensor -G28-
Installation only possible in one position;
bore holes are offset
7 - Sensor wheel screws
Always replace
Always replace sensor wheel when bolts
are removed
13-48
8 - Needle bearing
9 - Crankshaft
Axial play when new: 0.07-0.23 mm (0.003-
0.009 in.)
- Radial clearance is measured using
Plastigage
New: 0.02-0.04 mm (0.0008-0.0016 in.)
Do not turn crankshaft when measuring
radial play
Crankshaft dimensions Page 13-52
13-49
Fig. 1 Removing and installing sensor wheel

- Always replace sensor wheel -2- when screws -1- are removed.
Note:
After tightening a second time, the attachment point of the
countersunk screws of the sensor wheel are so deformed that the
screw heads sit against crankshaft (arrows) -3- and the sensor wheel
is loose underneath the screws.
Installation of the sensor wheel is only possible in one position; bore
holes are offset.
Tightening torque

Sensor wheel to crankshaft 10 Nm (7 ft lb) + 90 1) 2)
1) Replace bolts.
13-50
Crankshaft needle bearing, removing

and installing
Note:
A pilot needle bearing must be installed in the

crankshaft of engines for vehicles with manual
transmission. Install if necessary.
A pilot needle bearing must not be installed in

the crankshaft of engines for vehicles with
automatic transmission. Remove if necessary.
21/1 Kukko puller and 22/1 Kukko support
or
10-202 puller
VW207C drift
or
3176 centering mandrel
Removing
- Pull out using puller -A-, e.g. 21/2 Kukko extractor and 22/1 Kukko
support or 10-202 puller.
13-51
Installing
- Drive in using VW207C drift and/or 3176 centering mandrel.

When needle bearing is installed, side with inscription must be visible.
Installation of needle bearing:
Dimension -a- = 1.5 mm (0.059 in.)
13-52
Reconditioning dimension Crankshaft journal diameter - mm (in.) Connecting rod journal diameter - mm (in.)

Basic dimension (nominal) 54.00 (2.126) 47.80 (1.882)
1st undersize (nominal) 53.75 (2.116) 47.55 (1.872)
2nd undersize (nominal) 53.50 (2.106) 47.30 (1.862)
3rd undersize (nominal) 53.25 (2.096) 47.05 (1.852)
Sealing flanges and flywheel/drive plate, removing and installing Page 1 of 20
13-47
Sealing flanges and

flywheel/drive plate, removing
and installing
Note:
For repairs to the clutch:

012/01W Front Wheel Drive, Repair Group 30

01A All Wheel Drive, Repair Group 30
1 - Sealing flange - front

Must be located on dowel sleeves
2 - 15 Nm
13-48
3 - Sealing ring
Do not oil sealing lip of oil seal
4 - Sump
5 - 15 Nm
6 - Cylinder block
Removing and installing crankshaft
Page 13-67 .
Dismantling and assembling pistons and
conrods Page 13-79 .
7 - Dual-mass flywheel/drive plate
Removing and installing dual mass
flywheel Page 13-62
Removing and installing drive plate
Page 13-64
Can only be installed in one position. Holes
are offset.
13-49
8 - Securing bolt for dual-mass flywheel or

drive plate
Always replace
Tightening torque for dual mass flywheel
Page 13-63
Tightening torque for drive plate (vehicles
with automatic gearbox) Page 13-66
9 - Intermediate plate
Must be located on dowel sleeves
Do not damage/bend when assembling
13-50
10 - 15 Nm
11 - Rear sealing flange with oil seal
With gasket for cylinder block
Do not oil sealing lip of oil seal
Make sure that the sealing lip of the sealing
ring is not folded back or damaged when
installing
Removal and installation, removing sump
Page 17-11
When installing, push guide sleeve from
repair kit onto crankshaft
13-51
Crankshaft oil seal on pulley end,

replacing
Oil seal extractor 3203

Holding tool 3415
Assembly tool T10053
13-52
Removing
Engine in vehicle

Page 13-1 .
- Unbolt stop for torque reaction support -arrows-.
- Remove toothed belt sprocket from crankshaft. To do this, counter hold

sprocket with 3415.
13-53
- Before applying oil seal extractor, thread central

bolt for toothed belt sprocket into crankshaft as
far as it will go.
- Remove inner section of oil seal extractor 3203

one turn out of outer section and lock with
knurled screw.
- Lubricate threaded head of oil seal extractor, place it in position and

exerting firm pressure, screw it into oil seal as far as possible.
- Loosen knurled screw and turn inner part against crankshaft until the
oil seal is pulled out.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
13-54
Installing
Note:
Do not lubricate sealing lip or outer

circumference of seal before pressing in.
- Place guide sleeve T10053/1 onto crankshaft journal.

- Slide oil seal over guide sleeve.
- Press sealing ring flush with central bolt of toothed belt sprocket and
pressure sleeve from T10053.
13-55
- Replace central bolt for toothed belt sprocket.
- Remove crankshaft toothed belt sprocket. To do this, counter-hold

toothed belt sprocket with 3415.
Note:
Contact surface between sprocket and crankshaft must be free of oil.
Do not oil bolt for crankshaft sprocket.
- Install ribbed belt and tensioner for ribbed belt Page 13-20 .
Tightening torque
Component Nm
Toothed belt sprocket to crankshaft 90 + 90 1)2)
1) Replace bolt
13-56
Front sealing flange, removing and

installing
Special tools, material and equipment
Holding tool 3415
Assembly tool T10053

Electric drill with plastic brush attachment
Protective goggles
Silicone sealant D 176 404 A2
13-57
Removing
Engine in vehicle

Page 13-1 .
CAUTION!
The air conditioner refrigerant circuit must

not be opened.
- Disconnect A/C compressor from bracket and

secure to body with wire.
- Unbolt bracket for A/C compressor -Item 5 -,

Page 13-15
- Unbolt stop for torque reaction support -arrows-.
13-58
- Remove toothed belt sprocket from crankshaft. To do this, counter hold

sprocket with 3415.
- Remove oil pan Page 17-11
- Remove bolts -1 to 6-.

- Pry sealing flange loose and remove.
- Carefully remove any remains of sealant from cylinder block.
13-59
- Remove remaining sealant from sealing flange with rotating plastic

brush.
WARNING!
Wear protective glasses.
- Clean sealing surfaces: they must be free of oil and grease.
Installing
Note:
The sealing flange must be installed within 5 minutes after applying

silicone sealant.
- Cut off nozzle of silicon sealant tube at front marking (diameter of

nozzle = approx. 3 mm).
Silicone sealant D 176 404 A2
13-60
- Apply bead of silicone sealant -arrow-onto clean sealing surface of

sealing flange, as illustrated (arrow).
Sealant bead width -arrows-: 2 to 3 mm
Note:
The bead of sealant must not be thicker than 3 mm, otherwise excess
sealant will enter the oil pan and obstruct the strainer in the oil intake line.
- Install sealing flange immediately, and tighten all bolts lightly.
Note:
Use guide sleeve T10053/1 to attach the sealing flange with sealing ring
installed.
- Tighten sealing flange bolts in diagonal sequence.

- Install oil pan Page 17-23 .
Note:
After assembly, the sealant must dry for approx. 30 min. Only then may
the engine be filled with oil.
13-61
- Install crankshaft oil seal Page 13-54 .
- Install toothed belt (adjust valve timing) Page

13-44 .
- Install bracket for A/C compressor -Item 5 -,

Page 13-15 .
Tightening torques
Component Nm
Sealing flange to cylinder block 15
Bracket for air conditioner compressor on
cylinder block
33
A/C compressor to bracket 25
13-62
Dual mass flywheel/drive plate,

Dual-mass flywheel
Counter-hold tool 10-201
Removing
- Reverse position of counter-hold tool 10-201 for loosening/tightening

bolts.
- Mark position of flywheel relative to engine.
- Unbolt flywheel.
13-63
Installing
Installation is carried out in the reverse order or

- Replace bolts.
Tightening torque
Component Nm
Dual-mass 22.5 mm 60 + 90 2)
flywheel 1)
on crankshaft 43 mm 1) 60 + 180
3)
1) Bolt length
3)180 = 1/2 turn
13-64
Drive plate
Counter hold VW 558

Hex bolt M8 x 45 and two M10 hex nuts
Caliper gauge or depth measure
Removing
- Secure counter hold tool VW 558 to drive plate with hex bolt M8 x 45 -
Item 2-. Place two M10 hex nuts between counter-hold tool and drive
plate.
- Mark position of drive plate relative to engine.
- Unbolt drive plate.
13-65
Installing
- Place drive plate in position with shim -2- and washer -1-. Lug -arrow-
must face towards torque converter.
- Insert at least 3 old securing bolts and tighten to 30 Nm.

Specified value: 18.9 to 20.5 mm
13-66
If nominal value is exceeded:
- Remove drive plate again and fit without shim -2-. Retighten bolts to 30
Nm.
- Measure distance again.
If specified value is attained:
- Install new bolts and tighten.
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90 1)
13-67
Crankshaft, removing and

installing
Note:
When working on the engine, it should be secured

to the engine stand using the engine bracket VW
540 Page 10-27 .
1 - Bearing shell
For cylinder block with oil groove
(mark).
Install new bearing plates for cylinder block
with the correct color coding Fig. 2,
Page 13-72
2 - Chain sprocket
For oil pump drive chain
13-68
3 - Bearing shell
For bearing cap without oil groove
(mark).
The crankshaft bearing plates in the
bearing covers are supplied as spare part
with the color coding "yellow"
4 - Thrust washers
For bearing 3
Different types for cylinder block and
bearing cap
Note locating arrangement
5 - 65 Nm + 1/ turn (90 ) further
4
Always replace
When measuring radial clearance of
crankshaft, tighten to 65 Nm but do not turn
further.
13-69
6 - Bearing cap
Bearing cap 1: Pulley end
Bearing cap 3 with recesses for thrust
washers
Bearing shell retaining lugs (cylinder
block/bearing cap) must be on the same
side
7 - 10 Nm + 1/ turn (90 ) further
4
Always replace
After each removal of the bolts replace
sensor wheel Fig. 1, Page 13-71
8 - Needle bearing
For vehicles with manual transmission
Pulling out and driving in Page 13-73
13-70
9 - Sensor wheel
For engine speed sensor -G28-
Can only be installed in one position. Holes
are offset
Always replace sensor wheel if securing
bolts have been loosened.
Removing and installing Fig. 1,
Page 13-71
10 - Crankshaft
Axial clearance new: 0.07 to 00.23 mm,
Wear limit: 0.30 mm
Check radial clearance with Plastigage ,
New: 0.02 to 0.04 mm, Wear limit: 0.15 mm
Do not rotate the crankshaft when checking
the radial clearance.
Crankshaft dimensions Page 13-76
13-71
Fig. 1 Removing and installing sensor wheel
Note:
Always replace sensor wheel -2- if securing bolts -1- have been
loosened..
If the securing bolts are tightened a second time, the seats for the
countersunk bolt heads in the sensor wheel will be distorted to such
an extent that the bolt heads will come into direct contact with the
crankshaft -3- (-arrows-) and the sensor wheel will only fit loosely
under the bolts.
The mounting holes are asymmetrically spaced, so it is only possible
to install the sensor wheel in one position.
Tightening torque
Component Nm
Sensor wheel to crankshaft 10 + 90 1)2)
1) Replace bolts
13-72
Fig. 2 Allocation of crankshaft bearing plates for cylinder block
The bearing plates with the correct thickness are allocated to the cylinder
block at the factory. Colored dots are used to mark the thickness of the
bearing plates.
Note:
Arrow points in direction of travel.
The position of each bearing thickness is marked with letters on the lower
sealing area of the cylinder block.
Letter on Color of bearing
cylinder block
S = Black
R = Red
G = Yellow
Note:
The crankshaft bearing cups in the bearing covers are supplied as spare
part with the color coding "yellow".
13-73
Crankshaft needle bearing, removing

and installing
Special tool VW 207 C
Special tool Kukko 21/1 (Item 1) and Kukko 22/1 (Item 4)

Depth gauge
13-74
Note:
A needle bearing must be installed in the

crankshaft on vehicles with a manual
transmission. Install needle bearing if
necessary.
The needle bearing must not be installed in the

crankshaft on vehicles with an automatic
transmission. Remove needle bearing if
necessary.
Removing
- Pull out needle bearing with Kukko 21/1 and Kukko 22/1.
13-75
Installing
- Drive in using 207c or centralizing pin 3176.

Lettering on needle bearing must be visible when installed
Installation depth of needle bearing
Distance a = 1.5 mm
13-76
(in mm)
Honing Crankshaft Conrod

dimension bearing journal
main journal
diameter
main journal
diameter
-0.017 -0.022
Basic 54.00 47.80
dimension
-0.037 -0.042
-0.017 -0.022
1st undersize 53.75 47.55
-0.037 -0.042
-0.017 -0.022
2nd undersize 53.50 47.30
-0.037 -0.042
-0.017 -0.022
3rd undersize 53.25 47.05
-0.037 -0.042
13-77
Chain sprocket, removing and installing
Sleeve 30-100
Two-arm puller, commercially available.
Protective gloves
Removing
- Remove oil pan Page 17-11 .

- Removing front sealing flange Page 13-56 .
- Disconnect chain wheel of oil pump, remove chain tensioner and chain
-Item 5 -, Page 17-3 .
- Pull chain sprocket off crankshaft with puller -2- (Use a suitable washer
-1- to protect end of crankshaft).
13-78
Installing

WARNING!
Wear protective gloves!
- Heat chain sprocket in heating appliance for

approx. 15 minutes to 220 C.
Note:
Installation position: wide collar on sprocket

facing toward engine
- Install chain sprocket on end of crankshaft using pliers and push onto
seat on crankshaft with drift sleeve 30-100.
Pistons and connecting rods, disassembling and assembling Page 1 of 8
13-79
Pistons and connecting rods,

disassembling and assembling
Note:
Oil spray jet and pressure relief valve Fig. 6,

Page 13-85
1 - Conrod bolt - 30 Nm + 1/ turn (90 )

4
further
Always replace
Oil threads and contact surface
To measure radial clearance use old bolt
To measure radial clearance tighten to 30
Nm but not further
13-80
2 - Connecting rod bearing cap

Mark cylinder number -B-
Installation position: Markings -A- face
towards pulley side
3 - Bearing shells
Upper bearing shell with oil bore for piston
bolt lubrication
Installation position Fig. 5, Page
13-85
(mark).
Axial clearance New: 0.10 to 0.35 mm,
Wear limit: 0.40 mm
Check radial clearance with Plastigage :
New: 0.01 to 0.05 mm, Wear limit: 0.12
mm. Do not rotate crankshaft when
checking radial clearance
13-81
4 - Connecting rod
Only replace as a set
Mark cylinder number -B-
Installation position: Markings -A- face
toward pulley side
With oil bore for piston pin lubrication
5 - Circlip
6 - Piston pin
If difficult to remove, heat piston to approx.
60 C
Remove and install with VW 222a
13-82
7 - Piston
Checking Fig. 3, Page 13-84
Mark installation position and cylinder
number.
Arrow on piston crown points to pulley end
Install using piston ring clamp.
Piston and cylinder dimensions Page
13-86
8 - Piston rings
Offset gaps by 120
Remove and install with piston ring pliers.
"TOP" must face piston crown
Check ring gap Fig. 1, Page 13-83
Check ring to groove clearance Fig. 2,
Page 13-83
13-83
Fig. 1 Checking piston ring gap

- Push ring squarely from above down to approx. 15 mm from bottom
end of cylinder. To do this, use a piston without rings.
Piston ring New Wear limit
Dimensions in mm
1. compression ring 0.20 to 0.40 0.8
Oil scraper ring 0.25 to 0.50 0.8
Fig. 2 Checking ring to groove clearance

- Clean groove before checking clearance.
Piston ring New Wear limit
Dimensions in mm
Oil scraper ring 0.03 to 0.06 0.15
13-84
Fig. 3 Checking piston

- Measure pistons approx. 10 mm from lower edge of skirt, at 90 to
piston pin axis.
Permissible deviation from nominal dimension: no more than 0.04 mm
Fig. 4 Checking cylinder bores
Use internal dial gauge 50 to 100 mm

- Take measurements at 3 positions in both lateral direction -A- and
longitudinal direction -B-.
Permissible deviation from nominal dimension: no more than 0.08 mm
13-85
Fig. 5 Location of bearing shell

- Install bearing shells centrally into connecting rod or into connecting
rod bearing cap.
Distance a = 3.0 mm
Fig. 6 Oil spray jet and pressure relief valve

1 - Oil spray jet (for piston cooling)
2 - Bolt with pressure relief valve - 27 Nm
Opening pressure 1.3 to 1.6 bar
13-86
Honing Piston Bore

dimension diameter diameter
Basic mm 80.950 1) 81.01
dimension
Oversize mm 81.450 1) 81.51
1)Dimension without graphite coating (thickness

0.02 mm). The graphite coating on the piston
skirts wears away.
Cylinder head bolts, conversion from inner 12-point to Polydrive Page 1 of 1
15-1
Cylinder head bolts,

conversion from inner 12-
point to Polydrive
Conversion of cylinder head bolts from inner 12-point to Polydrive
bolts. Conversion is a running-change
A - Bolt with inner 12-point (old version). Remove and install using socket
insert 3410
B - Bolt with Polydrive head (new version). Remove and install using
Polydrive key 3452
Note:
Before removing or installing the cylinder head bolts, check which version
of the bolt is installed.
Special tool -B- is inserted in a socket insert -A- for assembly.
A - 10 mm socket insert (locally available)

B - Polydrive key 3452
Cylinder head bolts tightening sequence and torques remain unchanged

Page 15-25 .
Cylinder head, removing and installing Page 1 of 42
15-1
Cylinder head, removing and

installing
Note:
Always replace the cylinder head bolts.
When performing repairs, replace seals,

gaskets, self-locking nuts and bolts which have
a specified tightening angle.
The hose connectors and hoses of charge air

system must be free of oil and grease before
assembling.
When installing an exchange cylinder head with

the camshafts installed, the contact surfaces
between bucket tappet and cam running
surface must be oiled after installation of the
cylinder head.
The plastic protectors fitted to protect the open

valves must only be removed immediately
before installing the cylinder head.
When installing a new cylinder head or cylinder

head gasket, drain off all the old coolant and re-
fill with new coolant.
Cylinder heads which have cracks between the

valve seats or between valve seat inserts and
the spark plug thread can be used further
without reducing service life, provided the
cracks do not exceed a maximum of 0.3 mm in
width, or when no more than the first 4 turns of
the spark plug threads are cracked.
15-2
Part I - Cylinder head components
1 - Cylinder head gasket

Replacing Removing cylinder head,
Page 15-20
Installation position: Part No. to cylinder
head
After replacing, fill with fresh coolant
2 - Cylinder head
Removing Page 15-20
Check for distortion Fig. 1, Page
15-7
Reworking dimension Fig. 2, Page
15-7
Installing Page 15-28 .
After replacing, fill with fresh coolant
15-3
3 - Oil deflector
Note installation position
4 - Cylinder head bolt
Always replace
Note sequence when loosening Page
15-27
Note sequence when tightening Page
15-30
5 - Cylinder head cover
6 - Ignition coil
7 - Cap
8 - Gasket
Replace if damaged or leaking
9 - 10 Nm
First tighten inner nuts
Tighten outer nuts diagonally
15-4
10 - Cylinder head cover gasket

Replace if damaged or leaking
Before installing gasket apply "AMV 174
004 01" to sealing points Fig. 3 and
Fig. 4, Page 15-8
11 - Gasket
Always replace
12 - Combi valve for secondary air inlet
With screw connection
13 - 10 Nm
14 - Coolant flange
With coolant temperature sensor
15 - 10 Nm
16 - O-ring
Always replace
15-5
Part II - Intake manifold components
1 - Gasket
Note installation position
Always replace
2 - 10 Nm
3 - 10 Nm
4 - O-ring
For injector
Always replace
5 - Fuel rail
With injectors
6 - Top coolant line
7 - 10 Nm
8 - 10 Nm
15-6
9 - O-ring
For top coolant line
Always replace
10 - 10 Nm
11 - Intake manifold
12 - 20 Nm
13 - Support
For intake manifold
15-7
Fig. 1 Check cylinder head for distortion.

- Use knife edge, straightedge and feeler gauge to measure at several
points.
Max. permissible distortion: 0.1 mm
Fig. 2 Reworking dimension for cylinder head
Reworking the cylinder head (shaving) is only permitted down to minimum

dimension -a-.
Minimum dimension -a- = 139.20 mm
15-8
Fig. 3 Seal connections between double bearing cap and cylinder

head
- Apply a small quantity of sealant AMV 174 004 01 to sides of joints -
arrows- on upper sealing surface of cylinder head.
Fig. 4 Seal connections between camshaft adjuster and cylinder

head
15-9
Intake manifold, removing and installing
Removing


switched off.

- Drain coolant Page 19-4 .
- Disconnect coolant hoses -1- and -3-.

- Unbolt coolant expansion tank -2- (-arrows-).
- Disconnect electrical wiring to coolant level display switch -F66- on
bottom of expansion tank.
15-10
- Unplug vacuum hoses -1 to 3-.

- Disconnect connectors as follows:
4 - on intake air temperature sensor -G42-
5 - for throttle valve control module -J338-
- Remove the air duct hose -6- from throttle valve control module.
- Remove retaining plate for recirculation valve for turbocharger -N249- -

1- from underneath intake line and secondary air inlet valve -N112 -2- -
arrows-.
Note:
The electrical connectors and vacuum hoses do not have to be

disconnected.
15-11
- Disconnect connector for Camshaft Position sensor -arrow-.
- Remove retaining bolts for fuel manifold and disconnect vacuum line
from fuel pressure regulator -arrows-.
- Remove fuel manifold together with injectors from intake manifold and
place it on a clean cloth at back of engine compartment.
Note:
Carefully protect the removed injectors from contamination.
15-12
- Disconnect coolant hoses from upper coolant

line.
- Move electrical wiring at top of coolant line

aside.
- Unbolt upper coolant line from intake manifold and coolant flange -
arrows- at back of cylinder head.
- Remove intake line support -arrows-.

- Disconnect hose -1- to ACF valve on intake line.
- Pull out oil dipstick.
- Remove bracket of guide line for oil dipstick.
15-13
- Remove suction hose from flange and

remove.
Note:
Plug intake ports on cylinder head with clean

cloths.
Installing

Note:
All cable ties which are released or cut open

when removing must be located in the same
position when installing.
Hose connections and hoses of charge air

system must be free of oil and grease before
assembling.
Replace seals and gaskets.
- Top up coolant Page 19-7 .
- After connecting battery, enter anti-theft code for

radio.
15-14
- Actuate all power window switches again for at

least one second in the "close" direction to
activate automatic open/close function.
- Perform throttle-valve control module

adaption:
Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel

Injection & Ignition, Engine Code(s): AWM ,
Repair Group 24
Tightening torques
Component Nm
Intake manifold to cylinder head 10
Support for intake to intake 20
manifold manifold
to bracket 20
Fuel manifold to intake manifold 10
Coolant line to coolant flange 10
Coolant line on intake line 10
Hose clamps for coolant hoses
2
Hose clamps for air duct hoses
3.5
15-15
Cylinder head cover, removing and

installing
Removing
- Remove air filter cover -arrow-.
15-16
- Remove bolts -arrows-.

- Remove air ducts -1- and -2-.
- Remove line of crankcase vent -1-.

- Disconnect hose of crankcase venting from cylinder head cover.
- Remove line -1- from combination valve for secondary air inlet on
cylinder head cover and from heat shield -3- (engine code ANB only).
- Slightly swivel secondary air inlet line to side.
15-17
- Disconnect Ground wire -2-.

- Disconnect connectors -3-.
- Move lines and hoses aside.
- Remove ignition coils -1-.
- Loosen 2 top retaining clamps for toothed belt guard.
- Loosen nuts -arrows- for cylinder head cover and remove cylinder head
cover.
15-18
Installing

Note:
Replace seals and gaskets.
Replace cylinder head cover gaskets if

damaged.


- First tighten inner nuts for cylinder head cover then tighten outer nuts
diagonally.
- Check that upper toothed belt guard is correctly seated.
15-19
Tightening torques
Component Nm
Cylinder head cover to cylinder head 10
Line of crankcase vent to cylinder
headcover
10
Line of secondary air inlet to cylinder head
cover
10
Hose clamps 2
15-20
Cylinder head, removing
Socket head fastener T10092
Pin T40011
15-21
Procedure
Engine in vehicle

Page 13-1 .
Note:
All cable ties which are released or cut open

when removing must be located in the same
position when installing.


switched off.
- Drain coolant Page 19-4 .
- Remove intake line Page 15-9 .
- Remove ribbed belt and tensioner for ribbed belt

Page 13-18 .
- Remove air filter cover -arrow-.
15-22
- Disconnect connectors as follows:

1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on air mass meter
3 - on solenoid valve for charge pressure control -N75-
- Disconnect hose connections, move wiring aside and remove air filter
housing -arrows-.
- Disconnect connector -arrow- from camshaft adjuster.
15-23
- Remove line of crankcase vent -1-.

- Remove hose of crankcase venting from cylinder head cover.
- Remove line -1- from combination valve for secondary air inlet on
cylinder head cover and from heat shield -3- (engine code ANB only).
- Slightly swivel secondary air inlet line to side.
- Remove heat shield.
- Remove bolts -1- and -2- of oil feed line.

- Remove bolts -3- for exhaust turbocharger.
15-24
- Disconnect connector -arrow- at coolant temperature sensor -G2-/-

G62-.
- Disconnect vacuum hose -arrow- from combination valve.

- Remove bolts -2- and -3- and remove coolant flange.
- Remove bracket -1- for oil feed line.
- Unclip all wiring from cylinder head and move clear to one side.
- Remove coolant hose going to heat exchanger (heater unit) at back of
cylinder head (first release retainers on connecting flange).
15-25
- Remove upper toothed belt guard Page 13-

35 .
- Set crankshaft to markings for TDC of No. 1 cylinder by turning central

bolt on crankshaft sprocket in direction of rotation -arrows-.
- Attach socket head fastener T10092 into tensioner.

- Only tension pressure piston of tensioner until piston is secured with
pin T40011.
- Remove toothed belt from camshaft sprocket.
15-26
- Disconnec Ground wire -2-.

- Move lines and hoses aside.
- Loosen nuts -arrows- for cylinder head cover and remove cylinder head
cover.
- Remove both oil deflectors.
15-27
- Loosen cylinder head bolts in correct sequence.

- Remove cylinder head.
15-28
Cylinder head, installing
Note:
Always replace the cylinder head bolts.
When performing repairs, replace seals,

gaskets, self-locking nuts and bolts which have
a specified tightening angle.
Secure all hose connections with the correct

hose clips (same as original equipment):
Parts List
If repairing, carefully remove any remains of

gasket material from the cylinder head and
cylinder block. Make sure that no long scores or
scratches are made on the surfaces.
Carefully remove any remaining emery and

abrasive material.
Remove new cylinder head gasket from

packaging, just before installation.
Handle gasket extremely carefully. Damaging
the silicone layer or the indented area will lead

to leaks.
No oil or coolant must be allowed to remain in

the blind holes for the cylinder head bolts in the
cylinder head.
- Before positioning cylinder head, set crankshaft and camshaft to TDC

of cylinder 1.
15-29
- Loosen bolts -1- and -2- on turbocharger bracket (about 2 full turns
each) to avoid stressing when installing cylinder head.
- Place cylinder head gasket in position.

Note position of centralizing pins in cylinder block -arrows-.
Check installation position of cylinder head gasket. The Part No.
should be legible from intake side.
- Position cylinder head.
15-30
- Insert cylinder head bolts and tighten by hand.
- Tighten cylinder head bolts in two stages in sequence shown as

follows:
- Tighten using torque wrench:
Stage 1: 40 Nm
- Tighten with rigid wrench:
Stage 2: 180 (1/2turn) further (2 turns of 90 further is

permissible)
Note:
It is not necessary to retighten cylinder head bolts after repairs have been
performed.
- Tighten exhaust turbocharger to exhaust manifold with new seal and

attach bracket to cylinder block Page 21-45 .
- Install cylinder head cover Page 15-18 .
Note:
Observe all instructions on removing and installing the toothed belt

Page 13-40 .
15-31
- Install ribbed belt and tensioner for ribbed belt

Page 13-20 .
- Install intake line Page 15-13 .
- Replace coolant Page 19-7 .
- After connecting battery, enter anti theft code for

radio.
- Actuate all power window switches again for at

least one second in the "close" direction to
activate the automatic open/close function.
- Perform throttle-valve control module

adaption:

Repair Group 24
15-32
Tightening torques
Component Nm
Support for intake to intake 20
manifold manifold
to bracket 20
Turbocharger to exhaust manifold 35 1)
2)
Turbocharger bracket to cylinder block
25
Turbocharger bracket to turbocharger
30
Hose clamps for coolant hoses
2
Hose clamps for air duct hoses
3.5
1) Replace bolts
2)Coat thread and head attachment area with

high temperature lubricant G 052 112 A3
15-33
Compression, checking
Spark plug spanner 3122 B
Compression tester VAG VAG 1763
15-34
Test conditions:
Engine oil temperature at least 30 C
Battery voltage at least 12.7 V
Test sequence


15-35
- Remove spark plugs with spark plug spanner

3122B.
- Disconnect connectors from all injectors.
- Fully open throttle valve.
- Check compression with compression tester

VAG VAG 1763.
Note:
Using the compression tester
Operating instructions
- Operate starter until tester shows no further

pressure increase.
Compression pressure values:
New Wear limit Permissible

difference between
cylinders
bar excess
pressure
bar excess bar excess

pressure pressure
9.0 to 14.0 7.5 max. 3.0
15-36
- Install spark plugs and ignition coils.
Note:
Replace gaskets for ignition coils if damaged.
- Check Diagnostic Trouble Code (DTC)

memory:

Repair Group 01
Note:
DTCs will have been recorded in the DTC

memory because the connectors have been
unplugged. Check and, if necessary, erase the
DTC memory after completing the test.
Tightening torques
Component Nm
Spark plugs in cylinder head 30
15-1
Special tools
The following special tools and test equipment are
required for these operations:
VW 295 Drift
3240 Seal extractor
3241 Seal installer
2085 Puller
VAG 1381 Compression
recorder
VW 387 Dial gauge holder
VW 653/3 Pressure hose
2036 Adjustable rod
15-2
VW 541/1 Lever
3047A Slide hammer
10-206 Drift
3120 Reamer - 7mm
Valve gear, servicing Page 1 of 99
15-1
Valve gear, servicing

Notes:
Cylinder heads which have cracks between the

valve seats or between valve seat inserts and
the spark plug thread can be used further
without reducing service life, provided the
cracks do not exceed a maximum of 0.3 mm in
width, or when no more than the first 4 turns of
the spark plug threads are cracked.
After installing new lifters the engine must not

be started for about 30 minutes (otherwise
valves will strike pistons). Turn crankshaft two
complete revolutions before starting.
Carefully apply a small amount of sealant D 454

300 A2 at the four end points of the sealing
surfaces on the cylinder head, using a small
screwdriver Fig. 1.
15-2
1 - Double bearing cap

Lightly coat with sealant 454 300 A2 before
installing from Page Page 15-16
2 - Exhaust camshaft bearing cap
With connection for oil feed line
Watch position of dowel sleeve
Note installation position and numbering
Page 15-75
Lightly coat last bearing cap (after the
chain) with sealant D 454 300 A2 before
installing
3 - 10 Nm
15-3
4 - Oil line outlet side

For lubricating bearing cap
Note installation position Fig. 3
5 - Exhaust camshaft
Checking axial clearance Page 15-86
Check radial clearance with Plastigage
(lifters removed) Wear limit: 0.1 mm Run-
out: 0.01 mm (maximum)
6 - Cap
Always replace
15-4
7 - Oil line, inlet side

Note installation position Fig. 2
For lubricating bearing cap
8 - Inlet camshaft bearing cap
With connection for oil feed line
Page 15-75
9 - Inlet camshaft
Checking axial clearance Page 15-86
Check radial clearance with Plastigage
(lifters removed) Wear limit: 0.1 mm Run-
out: 0.01 mm (maximum)
10 - Drive chain
Installing Page 15-75
15-5
11 - 10 Nm
12 - Mechanical camshaft adjuster
With camshaft adjustment valve -N205
Secure with special tool 3366 before
removing Page 15-75
13 - Hydraulic lifter
Notes Page 15-88
Removing and installing with cylinder head
installed Page 15-75
14 - Valve cotters
15 - Valve spring plate
16 - Valve spring
15-6
17 - Valve stem seal

Replacing with cylinder head installed
Page 15-90
18 - Rubber/metal gasket
Always replace
19 - Seal
Always replace
20 - Cylinder head
Checking for distortion Page 15-56
Reworking Page 15-57
21 - Exhaust valve
22 - Inlet valve
23 - Oil seal (Hall sensor end)
Always replace Page 15-10
15-7
24 - Rotor for Hall sensor

Note position (notch on camshaft)
25 - Washer
Conical
26 - 25 Nm
27 - Hall sensor
28 - 10 Nm
29 - 30 Nm +180 (1/2 turn)
31 - Oil seal (toothed belt end)
15-8
Fig. 1 Sealing end points of joints between bearing caps and

cylinder head
Carefully apply a small quantity of sealant D 454 300 A2 at the four end
points of the sealing surfaces on the cylinder head -arrows-, using a small
screwdriver.
Fig. 2 Installation position of the oil line for the inlet camshaft
When connections are incorrectly allocated, bore holes in the oil line are
exposed (arrows).
To mount correctly, turn the oil line 180 and slide connections over bore
holes.
15-9
Fig. 3 Installation position of the oil line for the outlet camshaft
When connections are incorrectly allocated, bore holes in the oil line are
exposed (arrows).
To mount correctly, turn the oil line 180 and slide connections over bore
holes.
CAUTION!
If the oil lines are mounted incorrectly, lubrication of the camshaft

bearing is no longer possible and the cylinder head must be
replaced.
15-10
Oil seals in cylinder heads, replacing
Oil seal for camshaft drive (left and right

cylinder heads)
Note:
If the oil seal on one side is leaking it is advisable

to replace the seals on both sides.
- Remove rear toothed belt guard.
- Pull out oil seal with oil seal extractor 3240.

- Do not apply oil to sealing lip or outer circumference of seal.
- Install guide sleeve 3241/2 (from tool set 3241) onto camshaft.
- Press seal flush into cylinder head using press sleeve 3241/1 and bolt
3241/3.
15-11
Oil seal at Hall sensor (right cylinder head)
- Remove intake hose going to air cleaner (arrows).
- Remove bolts -arrows- and remove engine cover panel -C-.
15-12
- Remove pressure line -1- (right side).
Note:
Watch position of retaining strip -2-.
- Unbolt Hall sensor housing (10 Nm).

- Remove bolt securing Hall sensor rotor (20 Nm) and carefully lever off
rotor with a screwdriver.
- Screw in bolt from oil seal extractor 2085/1.
15-13
- Pull out seal with oil seal extractor 2085 and bolt 2085/1.
Do not apply oil to sealing lip or outer circumference of seal before
installing.
- Install guide sleeve (from tool set 3241) onto camshaft.
- Press in seal until flush using press sleeve 3241/1 and bolt 3241/3.
Installing
Install in reverse sequence.
Note:
When installing Hall sensor rotor, ensure that locating lug engages in slot
in camshaft.
15-14
Removing oil seal at Hall sensor (left cylinder

head)
- Detach coolant reservoir -arrows- and move clear to side.
Note:
Leave coolant hoses connected.
- Unplug connector from coolant level monitor.

- Move wiring harness clear at bulkhead.
- Unbolt bracket -arrows- for plug connectors on bulkhead and move

clear to side.
15-15
- Unbolt Hall sensor rotor (20 Nm) and carefully

lever off rotor using a screwdriver.
- Screw in bolt from 2085/1 oil ring extractor.
- Pull out seal with oil seal extractor 2085 and bolt 2085/1.
Do not apply oil to sealing lip or outer circumference of seal before
installing.
- install guide sleeve (from tool set 3241) onto camshaft.
15-16
- Press in seal until flush using press sleeve 3241/1 and bolt 3241/3.
Installing
Install in reverse sequence.
Note:
When installing Hall sensor rotor, ensure that locating lug engages in slot
in camshaft.
15-17
Rear oil seal and sealing flange (left cylinder

head)
Note:
Rear sealing flange and oil seal on left-hand

cylinder head must be replaceed together as
follows:
- Remove bolts -arrows- and remove engine cover panels -A...C-.
- Remove air duct -arrows-.
15-18
- Remove coolant reservoir -arrows- and move it clear to the side.
Note:

- Move wiring harness clear at bulkhead.
- Unbolt bracket -arrows- for plug connectors on bulkhead and move

clear to the side.
- Remove bolt securing Hall sensor rotor (20 Nm) and carefully lever off
rotor using a screwdriver.
15-19
- Remove cover panel from cylinder head cover

(cylinder bank 4-6).
- Release hose clamp -arrow-.

- Remove upper section of intake line -1-.
- Disconnect hose -2-.
- Disconnect hose (arrow).

- Remove bolt securing toothed belt guard from cylinder head cover.
- Pull plug connectors off ignition coils.
- Pull crankcase breather off cylinder head cover.
- Remove cylinder head cover.
15-20
- Remove double bearing cap -arrows-.

- Take out oil seal and sealing flange.
- Clean contact surfaces and sealing surfaces of double bearing cap.
- Apply a thin coating of sealant 454 300 A2 to shaded areas on double

bearing cap (see illustration), install bearing cap and tighten bolts to 10
Nm.
15-21
- Install guide sleeve (from tool set 3241) onto

camshaft.
- Press in oil seal until flush using press sleeve 3241/1 and bolt 3241/3.
- Carefully knock in sealing flange against stop using 3202 and a plastic
hammer.
Installing
Install in reverse sequence; note the following points:
- Seal end points of joints between bearing caps and cylinder head.
- Before installing cylinder head cover and gasket, carefully apply a
small quantity of sealant D 454 300 A2 at four end points of sealing
surfaces on cylinder head -arrows-, using a small screwdriver.
15-22
Cylinder head covers, removing and

installing
Removing and installing left cylinder head

cover
Removing
15-23
Note:

- Remove cover panel from cylinder head cover (cylinder bank 4 - 6).

- Remove intake line -1-.
- Detach water line -3-.
Note:
Plug lower section of intake line.
15-24
- Pull off hose -1-.

- Pull crankcase breather off cylinder head cover.
- Remove ignition coils.
Installing
Install in reverse sequence; note the following points:
15-25
Removing and installing right cylinder head

cover
Removing

- Remove cover above air cleaner.
15-26
WARNING!
Fuel system is under pressure. Before

opening the system, place a cloth around the
connection. Then release pressure by
carefully loosening the connection.
- Disconnect fuel supply line and fuel return line -1- and -2-, and move
fuel lines clear.
- Pull hose off EVAP valve -3-.
- Unplug connector -1- from air mass meter.

- Unplug connectors -2- from ignition output stages, and move wiring
clear.
- Remove air cleaner.
15-27
- Remover cover panel from right-hand cylinder head cover -arrows-.

- Detach upper section of intake line -3-.
Note:
15-28
- Remove bolt securing toothed belt guard from

cylinder head cover.
- Unplug connectors from ignition coils.
- Pull crankcase breather off cylinder head

cover.
Installing
Install in reverse sequence; note the following

points.
15-29
Cylinder head, removing and installing
Removing and installing left cylinder head
Notes:
All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace all seals and gaskets
Removing
- Remove engine Page 10-1 .
- Unplug connector from air recirculation valve -2-.
15-30
- Unplug connector for camshaft timing control -1- (cylinder bank 4..6).
- Unplug connectors from injectors -2- (cylinder bank 4..6).
- Unplug connectors from ignition coils -3- and move wiring harness
clear (cylinder bank 4..6).
- Pull crankcase breather -4- off cylinder head cover (cylinder bank 4..6).

- Pull off hose -5- going to turbocharger intake side.
15-31
- Unclip solenoid valve for charge pressure control -1-.

- Pull connector off EVAP valve -2-.
- Pull connector off throttle unit -1-.

- Pull connector off charge air sensor -2-.
- Pull off crankcase breather -3-.
- Pull connector off intake air temperature sensor -4-.
15-32
- Remove pressure lines -1-.
Note:

- Remove toothed belt guards -2- (left and right).
- Remove toothed belt guard -3- (center).
15-33
Note:

TDC drilling in the crankshaft must be visible (or able to be felt) in line
with the sealing plug hole.
tighten.
15-34
Note:
damper.

15-35
Notes:

when reinstalled.

- Using a hexagon key, turn toothed belt tensioning roller -1- clockwise 8
mm in direction of arrow until tensioning lever -2- compresses
tensioning element -3- sufficiently to enable a 2mm dia. spring pin to be
installed in the drilling and in the plunger.
- Insert spring pin and release toothed belt tensioning roller.
Use spring pin from 2024 A.
- Insert camshaft clamp 3391 in securing plates of two camshafts.
- Loosen both camshaft bolts and remove approx. 5 turns.
15-36
- Unbolt rear left toothed belt guard -arrows-.

- Detach intake manifold using special tool 3249.
- Unbolt cylinder head lifting bracket with coolant line -arrows- from
cylinder head.
15-37
- Unbolt water line -1- and pull it towards the rear.

- Unbolt bracket -2- from cylinder head.
- Remove heat sensor -2-.
- Unbolt turbocharger -1- from exhaust manifold (3 bolts).
15-38
- Unbolt coolant line at front of cylinder head -arrows-.

- Unbolt cylinder head cover.
- Loosen and remove cylinder head bolts in opposite sequence to
tightening sequence using special tool 3452 (Polidrive).
- Carefully lift off cylinder head.
Note:
Use special tool 3452 together with a normal commercial 10 mm socket

when removing and installing.
15-39
Installing
Notes:
Do not allow any oil or coolant to remain in the

blind holes for the cylinder head bolts in the
cylinder block.
Replace cylinder head bolts.
Connecting vacuum hoses Page 10-28 .
When installing a new cylinder head:
- Screw in centering pin for intake manifold.
The cylinder head supplied as a replacement

part can be used on both sides (left or right). But
a sealing cap (core plug) must be installed in the
front end of the cylinder head in each case.
- Coat outside circumference of sealing cap (core

plug) with sealant AMV 188 001 02.
- Using drift VW 295, knock in sealing cap (core plug) until outside rim is
flush with end of chamfer in cylinder head.
15-40
- Before installing cylinder head in position, turn

crankshaft and camshafts to TDC of No. 3
cylinder.
- Install cylinder head gasket on dowel sleeves.

The marking "oben" (top) or part number must
face towards cylinder head.
- Install cylinder head, insert cylinder head bolts

and tighten finger-tight.
- Tighten cylinder head bolts in two stages in sequence shown, as

follows:
Stage 1 = 60 Nm.
Stage 2 = turn a further 1/2 turn (180 ) with a rigid wrench (turning
2 x 90 is also permissible).
It is not necessary to torque down cylinder head bolts again after repairs
have been completed.
15-41
Tightening torques
Component Nm
Bolts M6 10
Bolts M8 20
Camshaft bearing caps and camshaft adjuster 10
Exhaust manifold to cylinder head 25
Front exhaust pipe to exhaust manifold 25
Oxygen sensor 50
Spark plugs 25
Toothed belt sprocket to camshaft 55
Cylinder head cover 10
15-42
Removing and installing right cylinder head
Notes:
All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace all seals and gaskets
Removing
- Remove engine Page 10-1 .
- Unplug connector from air recirculation valve -2-.
15-43
- Remove cover panel from right-hand cylinder head cover -arrows-.

- Unbolt upper section of intake line -3-.
Note:
15-44
- Unplug connector for camshaft timing control -1- (cylinder bank 1..3).
- Unplug connectors from ignition coils -3- and move wiring harness
clear (cylinder bank 1..3).
- Pull crankcase breather -4- off cylinder head cover (cylinder bank 1..3).
- Pull off hose -5- going to turbocharger intake side.
15-45
- Unclip solenoid valve for charge pressure control -1-.

- Pull connector off EVAP valve -2-.
- Pull connector off throttle unit -1-.

- Pull connector off charge air sensor -2-.
- Pull off crankcase breather -3-.
- Pull connector off intake air temperature sensor -4-.
- Pull connector -5- off Hall sensor.
15-46
- Remove pressure lines -1-.
Note:

- Remove toothed belt guards -2- (left and right).
- Remove toothed belt guard -3- (center).
15-47
Note:

The TDC drilling in the crankshaft must be visible (or able to be felt) in
line with the sealing plug hole.
tighten.
15-48
Note:
damper.

15-49
Notes:

when reinstalled.

- Using a hexagon key, turn toothed belt tensioning roller -1- clockwise 8
mm in direction of arrow until tensioning lever -2- compresses
tensioning element -3- sufficiently to enable a 2mm dia. spring pin to be
installed in drilling and in plunger.
- Insert spring pin and release toothed belt tensioning roller.
Use spring pin from 2024 A.
- Insert camshaft clamp 3391 in the securing plates of the two
camshafts.
- Loosen both camshaft bolts and remove approx. 5 turns.
15-50
- Unbolt rear right toothed belt guard -arrows-.

- Detach intake manifold using special tool 3249.
- Unbolt water line -1- and pull it towards the rear.

- Unbolt bracket -2- from cylinder head.
15-51
- Detach line -arrow- from cylinder head.

- Detach line -2-.
- Remove turbocharger -arrows-.
15-52
- Unbolt cylinder head cover.
- Loosen and remove cylinder head bolts in

opposite sequence to tightening sequence using
special tool 3452 (Polidrive).
Note:
Use special tool 3452 together with a normal commercial 10 mm socket

when removing and installing.
15-53
Installing
Notes:
Do not allow any oil or coolant to remain in the

blind holes for the cylinder head bolts in the
cylinder block.
Install new cylinder head bolts.
Connecting vacuum hoses Page 10-28 .
- Screw in centering pin for intake manifold.


15-54
- Before installing cylinder head in position, turn

crankshaft and camshafts to TDC of No. 3
cylinder.
- Install cylinder head gasket on dowel sleeves.

Marking "oben" (top) or part number must face
towards cylinder head.
- Install cylinder head, insert cylinder head bolts

and tighten finger-tight.

follows:
Stage 1 = 60 Nm.
Stage 2 = turn a further 1/2 turn (180 ) with a rigid wrench (turning
2 x 90 is also permissible).
It is not necessary to torque down cylinder head bolts again after repairs
15-55
Tightening torques
Component Nm
Bolts M6 10
Bolts M8 20
Camshaft bearing caps and camshaft adjuster 10
Exhaust manifold to cylinder head 25
Front exhaust pipe to exhaust manifold 25
Oxygen sensor 50
Spark plugs 25
Toothed belt sprocket to camshaft 55
15-56
Cylinder head, checking for distortion
- Measure at several points with straight-edge.

Maximum permissible distortion: 0.1 mm.
15-57
Cylinder head, reworking
Reworking cylinder head (skimming) is only permissible down to a

minimum dimension of a =139.25 mm.
15-58
Test requirements:
Engine oil temperature at least 30 C.
Battery fully charged.
15-59
Note:

- Remove cover panel from cylinder head cover (cylinder bank 4 - 6).

- Remove intake line -1-.
- Detach water line -3-.
Note:
15-60
- Pull off hose -1-.
WARNING!
Fuel system is under pressure. Before opening the system, place a

cloth around the connection. Then release pressure by carefully
loosening the connection.
- Disconnect fuel supply line and fuel return line -1- and -2-, and move
fuel lines clear.
- Pull hose off EVAP valve -3-.
15-61
- Unplug connector -1- from air mass meter.

- Unplug connectors -2- from ignition output stages, and move wiring
clear.
- Remove air cleaner.
- Remover cover panel from right-hand cylinder head cover -arrows-.
15-62

- Detach upper section of pressure line -3-.
Note:
Plug lower section of pressure line.
15-63
- Pull crankcase breathers off cylinder head

covers.
- Unplug connectors from all 6 injectors.
- Disconnect 5-pin connecter at power output

stage of ignition coils.
- Open throttle fully.
- Use compression tester VAG 1381 or VAG

1763.
- Operate starter until pressure reading on tester

no longer rises.
Compression pressure values
New Wear Max. permissible difference

limit between cylinders
9 ... 13 7 bar 3 bar
bar
15-64
Installing
Install in reverse sequence; note the following

points.
- install fuse No. 28 (for fuel pump).
- Erase Diagnostic Trouble Code (DTC)

memory.
Note:
Malfunctions will have been stored in the

memory because the connector to the Hall
sensor has been unplugged. Therefore
interrogate and erase the DTC memory after the
test.
Tightening torque
Component Nm
Ignition coils to cylinder head 10
Spark plugs in cylinder head 30
15-65
Sealing cap (core plug) in cylinder head,

installing


15-66
Camshaft adjustment, checking function
VAS 5051 with VAG 5051/1

or
VAG 1551 with VAG 1551/3A
Test requirement:
WARNING!
During a road test in an airbag-equipped vehicle, test equipment

must always be fastened to and operated from the rear seat by a
second technician.
When driving or riding in an airbag-equipped vehicle, NEVER hold
the scan tool or other test equipment in your hands or lap while in
motion. Objects between you and the airbag increase the risk of
injury in an accident.
15-67
Test sequence
- Connect VAS 5051 tester or VAG 1551 scan

tool and select control module for engine
electronics using "address word" 01. Engine
must run at idle for this.
Repair Manual, 2.7 Liter V6 5V BiTurbo Fuel

Injection & Ignition, Engine Code(s): APB, Repair
Group 01

Select Function XX
Initiate basic setting Q When indicated on display


1 2 3 4
Camshaft adjustment is checked for function.
- Increase engine speed to above 2000 RPM.
15-68
Display fields
1 2 3 4
Display group 94: Function of camshaft adjustment
Display 1 RPM Text Text Text
Indicated Engine speed (RPM) Camshaft adjustment Test result, Bank 1 Test result, Bank 2
Specified value >2000 Cs-CM. ON Test ON Test ON
Sys. OK Sys. OK
Note:
If "not OK" is indicated in display field 3 and/or 4:
- Check solenoid valve for camshaft

adjustment.
15-69
Solenoid valve for camshaft adjustment,

checking
VAG 1526A
VAG 1527B
VAG 1594A
VAG 1598/31
VAS 5051
- or
VAG 1551 with VAG 1551/3A
15-70
- Initiate output Diagnostic Test Mode (DTM) and

activate the valve for camshaft adjustment.
Repair Manual, 2.7 Liter V6 5V BiTurbo Fuel

Injection & Ignition, Engine Code(s): APB, Repair
Group 01
If valves do not click during output Diagnostic

Test Mode (DTM):
Checking internal resistance
- Remove bolts (arrows) and remove engine covers -A- and -B-.
- Remove air distributor (arrows).
15-71
- Disconnect connector from solenoid valve.
- Connect multimeter at valve for resistance measurement.

Specified value: 10 ... 18
- Replace valve.
Checking voltage supply
- Disconnect connector from solenoid valve.
- Connect VAG 1527B voltage tester as follows:
Harness connector Measure to
terminal
1 Engine Ground (GND)
- Operate starter briefly.
LED must light.
If LED does not light:
- Perform following tests marked with dots:

Check fuse of solenoid valves for camshaft adjustment.
15-72
Check wire connection from terminal 1 of connector via fuse -S234-

(in fuse holder, socket 34) to Fuel Pump (FP) relay for open circuit:
- Repair open circuit if necessary.
If no malfunctions are detected:
- Check Fuel Pump (FP) relay.
Repair Manual, 2.7 Liter V6 5V BiTurbo Fuel Injection & Ignition,

Engine Code(s): APB, Repair Group 24
15-73
Checking activation
- Connect VAG 1527B voltage tester between terminal 1 (+) and 2.

- Initiate output Diagnostic Test Mode (DTM) and activate valve for
camshaft adjustment.

LED must blink.
If LED does not blink or if it remains constantly lit:
- Connect VAG 1598/31 test box at wiring harness to ECM, do not

connect ECM.

15-74
- Check following wire connections for open circuit and short circuit to
Ground (GND) and B+:
Valve 1 for camshaft adjustment -N205- and valve 2 for camshaft

adjustment -N208-
Harness connector VAG 1598/31 or test box

terminal
Bushing
2 Electrical Wiring Diagrams, Troubleshooting
&Component Locations
- Repair Ground (GND) connection or open circuit if necessary.
If wire connection is OK:
- Replace Engine Control Module (ECM).

If no malfunctions are detected:
- Replace mechanical camshaft adjuster.
15-75
Camshafts and camshaft adjusters,

Removing
Cylinder head installed
- Remove noise insulation panel -arrows-.

- Remove front bumper
- Move lock carrier to service position

Left cylinder head
- Remove left-hand cylinder head cover Page 15-22 .
15-76
Right cylinder head
- Remove right-hand cylinder head cover Page

15-25
All:
- Remove bolt securing Hall sensor rotor (20 Nm)

and carefully lever off rotor using a screwdriver.
- Insert camshaft clamp 3391 in securing plates of

two camshafts.
- Loosen both camshaft bolts and remove approx.

5 turns.
15-77

- Using a screwdriver, carefully pry oil feed lines for camshaft bearings
out of camshaft bearings.
Make sure that the retaining catches do not break off when levering out
the oil lines.
- Secure camshaft adjuster using retainer for chain tensioner 3366.
Note:
Do not over tighten retainer for chain tensioner, otherwise camshaft

adjuster can be damaged.
15-78
- Check TDC position of camshafts once again.
Note:
The two markings on the camshafts must be in line with the two arrows on
the bearing caps.
- Clean drive chain and camshaft chain sprockets in vicinity of arrows on

bearing caps and mark position of chain on sprockets with paint
opposite two arrows.
Notes:
The distance between the two arrows (and thus between the paint
markings) is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly towards the inside
in relation to chain roller -1-.
Do not mark the chain with a center punch or by making a notch or
similar.
15-79
- Remove bolts securing camshaft adjuster -6-.

- Remove bearing caps 1, 3, 5 and 7 from inlet and exhaust camshafts
and place them in correct order on a clean surface.
- Loosen bearing caps 2 and 4 alternately and in diagonal sequence,
and remove from both camshafts.
- Take out both camshafts together with camshaft adjuster.
Installing
- Replace rubber/metal gasket for camshaft adjuster and apply a thin

coat of sealant D 454 300 A2 to the shaded area.
15-80
- Install drive chain on camshaft sprockets as

follows:
When the old chain is being used again, install the chain so that
the paint markings (arrow) are in line.
When a new chain is being installed, the distance between the

notches -A- and -B- on the camshafts must be 16 rollers on the
chain. The illustration shows the exact positions of the 1st and 16th
rollers on the sprockets.
Notch -A- is offset slightly towards the inside in relation to chain
roller -1-.
- Insert camshaft adjuster inside chain (second mechanic required).
- Locate camshafts with chain and camshaft adjuster in cylinder head.
- Oil camshaft bearing surfaces.
15-81
Notes:
The dowel sleeves for the bearing caps and

camshaft adjuster must be in the cylinder head.
Install the bearing caps so that the markings on

the bearing caps can be read from the inlet side
of the cylinder head.
- Tighten bolts securing chain tensioner (watch

position of dowel sleeves).
- Tighten bearing caps 2 and 4 of inlet and exhaust camshafts

alternately and in diagonal sequence (watch position of dowel sleeves).
- Install two bearing caps next to chain sprockets on inlet and exhaust
camshafts.
15-82
- Check correct setting of camshafts:
The two markings on the camshafts must be in line with the two
arrows on the bearing caps -arrows-.
The distance between the two arrows on the bearing caps (or
between the paint markings) is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly towards the
inside in relation to chain roller -1-.
15-83
- Prepare shaded areas on double bearing cap -1- and bearing cap -7-.
.... by applying a thin coat of sealant D 454 300 A2 and install bearing
caps (watch position of dowel sleeves).
- Install remaining bearing caps (watch position of dowel sleeves).
- Install new oil feed lines for camshaft bearings.
- Install new oil seals for inlet and exhaust camshafts; installing Page
15-10 .
- Remove retainer for chain tensioner 3366.
15-84
Notes:
When new lifters have been installed the engine

must not be started for about 30 minutes. The
hydraulic compensation elements must settle
(otherwise valves will strike pistons). Then turn
crankshaft two full revolutions before starting.
After working on the valve gear, turn over the

engine carefully at least two revolutions by
hand to ensure that none of the valves make
contact when the starter is operated.
15-85
- Install cylinder head covers Page 15-22 .
- Install toothed belt Page 13-4 .
Tightening torques
Component Nm
Bolts M6 10
M8 20
Except for the following:
Bearing caps to cylinder head 10
Camshaft adjuster to cylinder head 10
Hall sensor rotor to camshaft 25
Hall sensor housing to cylinder head 10
Camshaft sprocket to camshaft 55
Camshaft bearing cap and camshaft 10
adjuster
15-86
Camshaft axial clearance, checking
- Remove camshafts Page 15-75 .
- Remove lifters.
- Install camshafts in cylinder head without drive

chain and secure by tightening bearing caps 2
and 4.
- Attach dial gauge to cylinder head with universal dial gauge bracket
VW 387.
- Press camshaft against dial gauge by hand.
- Set dial gauge to -0-.
- Press camshaft away from dial gauge.
- Note reading on gauge:
New Wear limit

0.05 ... 0.15 mm 0.20 mm
15-87
Valve dimensions, checking
Note:
Valves must not be reworked. Only grinding-in (lapping) is permitted.
Dimension Inlet valve Exhaust valve

a = diameter mm 26.8 ... 27.0 29.8 ... 30.0
b = diameter mm 5.96 ... 5.97 5.94 ... 5.95
c = mm 104.84 ... 105.34 103.64 ... 104.14
= 45 45
WARNING!
Worn sodium-cooled exhaust valves must be treated as follows

before disposal:
Saw the valves into two sections with a metal saw at a point
between the center of the valve stem and the valve head. The
valves must not come into contact with water when this is done.
Then throw the valves into a bucket of water (not more than ten at
a time) and step back, because a chemical reaction occurs when
the sodium filling burns. After this treatment the valves can be
disposed of in the normal way.
15-88
Hydraulic lifters, checking
Notes:
Replace malfunctioning lifters completely (lifters

cannot be adjusted or repaired).
When new lifters have been installed the engine

must not be started for about 30 minutes
(otherwise valves will strike pistons).
Irregular valve noises when starting engine are

normal.
- Start engine and run until coolant temperature

reaches approx. 80 C.
- Increase engine speed to about 2500 RPM for

approx. 2 minutes: if necessary, perform road
test.
If the hydraulic lifters are still noisy, locate

malfunctioning lifters as follows:
- Rotate crankshaft clockwise by turning securing

bolt for toothed belt sprocket until cams of lifters
to be checked are pointing upward.
15-89
- Measure clearance between cam and lifter.
- Push lifter down with a wooden or plastic wedge. If a 0.20 mm feeler

gauge can then be inserted between camshaft and lifter, replace lifter:
removing and installing camshafts and camshaft adjuster Page 15-
75
Note:
If irregular valve noise occurs repeatedly during short journeys and

disappears after extended driving, the oil check valves must be replaceed
Page 17-12 .
15-90
Valve stem seals, replacing
- Remove camshafts Page 15-75 .
- Remove lifters and put them down with the

contact surface downwards. Ensure that lifters
are not interchanged.
- Remove spark plugs.
- Set piston of relevant cylinder to bottom dead

center (BDC).
Note:
Tight cotters can be released by tapping lightly

on the valve lever with a hammer.
15-91
Exhaust side
Note:
Before attaching the valve assembly appliance,

remove the two studs in the center of the cylinder
head and the three upper studs (inlet side) for
securing the cylinder head cover.
- Screw pressure hose VW 653/3 with sealing ring

finger-tight into spark plug thread of relevant
cylinder, and maintain a constant pressure of at
least 6 bar.
- Attach valve assembly appliance 2036 as illustrated: use M6 x 40 bolts

with large washers.
- Remove valve spring using valve lever VW 541/1 and thrust piece VW
541/5.
- Take out valve spring and valve spring plate.
- Pull off valve stem seal with 3047 A.
15-92
- To prevent damage to the new valve stem seals, place plastic sleeve -
A- on the valve stem.
- Lightly oil sealing lip.
- Insert valve stem seal -B- (without oiling outside of seal) into installing
tool 3129 and carefully push it down onto the valve guide.
- When installing new valves, lightly oil valve stems before installing.
Inlet side
Note:
The inlet valves are installed in the cylinder head at different angles.
Valve spring compressor 3362 can be set accordingly to two different

positions:
1 - Upper position for center valve

2 - Lower position for the two outer valves
3 - Threads on each side to take M6 x 25 bolts for securing spring
compressor to cylinder head
15-93
- Mount spring compressor 3362 on cylinder head with two bolts

supplied, as in illustration.
- Screw pressure hose VW 653/3 with sealing ring finger-tight into spark
plug thread of relevant cylinder, and maintain a constant pressure of at
least 6 bar.
- Set position of spring compressor for relevant valve, and remove valve
spring using threaded spindle.
- Pull off valve stem seal using 3364.
15-94
- To prevent damage to new valve stem seals, place plastic sleeve -A-
on valve stem.
- Lightly lubricate sealing lip with oil.
- Insert valve stem seal -B- (without oiling outside of seal) into installing
tool 3365 and carefully push it down onto valve guide.
- When installing new valves, lightly oil valve stems before installing.
Reworking valves
Valves must not be reworked. Only grinding-in (lapping) is permitted.
WARNING!
Note precautions required when disposing of sodium-cooled

exhaust valves Page 15-87 .
15-95
Valve guides, checking
When repairing engines or cylinder heads with

leaking valves, it is not sufficient to reface the
valve seats and replace the valves. The valve
guides must also be checked for wear. This is
particularly important on high-mileage engines.
- Insert valve into valve guide so that end of valve stem is flush with end
of guide. The valve stems have different diameters, so only use an inlet
valve in an inlet guide and an exhaust valve in an exhaust guide.
- Measure amount of rock.
Wear limit
Inlet valve guide Exhaust valve guide

0.8 mm 0.8 mm
If the wear limit is exceeded, replace cylinder head.
15-96
Valve seats, reworking (refacing)
Notes:
The valve seats should only be reworked just

enough to produce a good seating pattern.
Calculate the maximum permissible reworking

dimension before reworking.
If the reworking dimension is exceeded, the

function of the hydraulic lifters can no longer be
guaranteed and the cylinder head should be
replaced.
Calculating maximum permissible reworking

dimension
- Insert valve and press firmly against valve

seat.
Note:
If the valve is to be replaced as part of a repair,

use a new valve for the calculation.
- Measure distance between end of valve stem and top surface of

cylinder head (illustration shows a 4-valve head).
-
Calculate maximum permissible reworking dimension from measured
distance and minimum dimension.
15-97
Minimum dimensions
Outer inlet Center inlet Exhaust
valve valve valve
32.2 mm 33.2 mm 33.0 mm
Measured distance minus minimum dimension =

maximum permissible reworking dimension.
Example
Center inlet valve
Measured distance 33.0 mm
Minimum dimension - 32.2
mm
Maximum permissible reworking = 0.8 mm
dimension
Note:
If the measured distance is less than the

minimum dimension, repeat the measurement
with new valves, or replace cylinder head.
15-1
Valve gear, servicing

WARNING!
Do not re-use any fasteners that are worn or

deformed in normal use.
Some fasteners are designed to be used only

once, and are unreliable and may fail if used
a second time. This includes, but is not
limited to, nuts, bolts, washers, circlips and
cotter pins. Always follow the
recommendations in this manual-replace
these fasteners with new parts where
indicated, and any other time it is deemed
necessary by inspection.
CAUTION!
After installing new hydraulic valve lifters the

engine must not be started for about 30
minutes (otherwise the valves will strike the
pistons). Turn the crankshaft two complete
revolutions by hand before starting.
15-2
Notes:
Cylinder heads with small cracks between the

valve seats that are less than 0.3 mm (0.012
in.) wide and/or between one valve seat and
only the first four threads of the spark plug
thread, can continue to be used without
reduced service life.
Carefully apply a small amount of sealant D 454

300 A2 at the four end points of the sealing
surfaces on the cylinder head using a small
screwdriver page 15-13 .
CAUTION!
Part numbers are listed here for reference

only. Always check with your Parts
department for the latest information.
15-3
Cylinder head without oil lines to camshaft

bearings

Lightly coat with sealant 454 300 02 A2
before installing page 15-36
2 - Bolt
10 Nm (7ft lb)
Watch guide sleeve
page 15-36
Lightly coat last bearing cap (after chain)
with D454 300 A2 sealant before installing
Checking axial clearance page 15-42
Check radial clearance using Plastigage
(hydraulic valve lifters removed):
Max. run-out: 0.01 mm (0.0004 in.)
15-4
5 - Cap
Always replace
6 - Intake camshaft bearing cap
page 15-36
7 - Intake camshaft
Max. run-out: 0.01 mm (0.0004 in.)
8 - Drive chain
Installing page 15-36
9 - Bolt
10 Nm (7ft lb)
With valve -1- for camshaft adjustment -
N205-
Secure using 3366 bracket tensioner
before removing page 15-31
15-5
11 - Hydraulic valve lifter (intake)

Notes page 15-45
12 - Valve keepers
13 - Valve spring retainer
14 - Valve spring
15 - Valve stem oil seal
page 15-47
16 - Rubber/metal seal
Always replace
17 - Seal
Always replace
18 - Cylinder head
Checking for distortion page 15-27
Resurfacing page 15-28
19 - Exhaust valve
20 - Intake valve
21 - Oil seal
Camshaft Position (CMP) sensor side
15-6
22 - Shutter wheel for Camshaft Position

(CMP) sensor -G40-
23 - Washer
Conical
24 - Bolt
25 Nm (18 ft lb)
25 - Camshaft Position (CMP) sensor -G40-
26 - Bolt
10 Nm (7 ft lb)
27 - Bolt
55 Nm (41 ft lb)
29 - Oil seal
Toothed belt side
30 - Hydraulic valve lifter
Notes page 15-45
installed page 15-31
15-7
Cylinder head with oil lines to camshaft

bearings

Lightly coat with 454 300 02 A2 sealant
before installing page 15-17
With oil line connector
Watch guide sleeve
page15-31
Lightly coat last bearing cap (after chain)
with D454 300 A2 sealant before installing
3 - Bolt
10 Nm (7 ft lb)
4 - Oil line
Exhaust side
From VIN 8D-W-005 001
For bearing cap lubrication
Note installed position Fig. 4
15-8
Max. run-out: 0.01 mm (0.0004 in.)
6 - Cap
Always replace
7 - Oil line
Intake side
From VIN 8D-W-005 001
Note installed position Fig. 3
For bearing cap lubrication
8 - Intake camshaft bearing cap
With oil line connector
page 15-36
15-9
9 - Intake camshaft
Max. run-out: 0.01 mm (0.0004 in.)
10 - Drive chain
Installing page 15-36
11 - Bolt
10 Nm (7ft lb)
With valve -1- for camshaft adjustment -
N205-
Secure using 3366 bracket tensioner
before removing page 15-31
13 - Hydraulic valve lifter (intake)
Refer to notes page 15-45
installed page15-31
14 - Valve keepers
15-10
15 - Valve spring retainer

16 - Valve spring
17 - Valve stem oil seal
page 15-47
18 - Rubber/metal seal
Always replace
19 - Seal
Always replace
20 - Cylinder head
Checking for distortion page 15-27
Resurfacing page 15-28
21 - Exhaust valve
22 - Intake valve
23 - Oil seal
Camshaft Position (CMP) sensor side
15-11
24 - Shutter wheel for Camshaft Position

(CMP) sensor -G40-
25 - Washer
Conical
26 - Bolt
25 Nm (18 ft lb)
27 - Camshaft Position (CMP) sensor -G40-
28 - Bolt
10 Nm (7 ft lb)
29 - Bolt
55 Nm (41 ft lb)
31 - Oil seal
Toothed gear side
15-12
Cylinder head with oil lines on the camshaft

bearings
Fig. 3 Installation position of intake camshaft oil line
If connectors are misaligned, oil line bores are exposed (arrows).
- To install correctly, turn oil line 180 and slide connectors over bores.
Fig. 4 Installation position of exhaust camshaft oil line
If connectors are misaligned, oil line bores are exposed (arrows).
- To install correctly, turn oil line 180 and slide connectors over bores.
CAUTION!
If the oil lines are incorrectly installed, the camshaft bearings will not
be lubricated and the cylinder head will have to be replaced.
15-13
All models
Sealing contact surfaces between bearing cap and cylinder head
- Carefully apply small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head (arrows) using small
screwdriver.
CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information.
15-14
Cylinder head oil seals, replacing
Oil seal for camshaft drive (left and right

cylinder heads)
- Rotate engine to Top Dead Center (TDC).
- Remove rear toothed belt guard.
- Remove seal using 3240 seal extractor.

Note:
Do not apply oil to sealing lip or outer circumference of seal.
- Install 3241/2 pull sleeve from 3241/1 press sleeve onto camshaft.
- Press seal flush into cylinder head using 3241/1 press sleeve and
3241/3 bolt.
15-15
Oil seal on Camshaft Position (CMP) sensor

(left and right cylinder head)
- Unbolt Camshaft Position (CMP) sensor.
- Unbolt shutter wheel for Camshaft Position

(CMP) sensor and carefully pry out using
screwdriver.
- Screw in bolt from 2085/1 adapter.
- Remove seal using 2085 seal puller and bolt from 2085/1.
Do not lubricate sealing lip or outer edge of seal before pressing in.
- Install pull sleeve from 3241 seal installer onto camshaft.
15-16
- Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
Rear sealing flange (left cylinder head)
The sealing flange and rear oil seal on the left cylinder head must be
replaced together as follows:
- Unbolt engine coolant expansion tank from bracket.

- Remove crankshaft ventilation line from cylinder head cover.
- Unbolt Camshaft Position (CMP) sensor.
- Unbolt shutter wheel for Camshaft Position (CMP) sensor G40 and
carefully pry out using screwdriver.
- Remove double bearing cap (arrows).

- Remove seal and sealing flange.
- Clean running and sealing surfaces as well as contact surface of
double bearing cap.
15-17
- Apply thin coat of sealant 454 300 A2 to hatched areas on double

bearing cap, install and tighten to 10 Nm (7 ft lb).
- Install pull sleeve from 3241 seal installer onto camshaft.
- Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
- Carefully drive in sealing flange to stop using 3202 retractor and plastic
hammer.
15-18
Cylinder head, removing and installing
Note:
The following instructions apply to the left

cylinder head.
Removing
Lock carrier in service position page 13-

1.

- Unbolt left and right-side front exhaust pipes from exhaust manifold.
- Unbolt exhaust system from transmission bracket.
15-19
- Place VAG1306 drip tray beneath engine.
- Open engine coolant expansion tank cap.
WARNING!
The cooling system is pressurized when the

engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.
- With bumper removed, open coolant drain plug (arrow) on lower left of
radiator by turning it counterclockwise. If necessary, attach accessory
hose to connection.
- With bumper installed, pull off retaining clamp for lower right radiator
hose (from radiator to engine) and disconnect radiator hose from
radiator.
- Using 3247 hex ball socket, open coolant drain plug on engine (arrow)
as well.
- Unbolt engine coolant expansion tank from bracket and lay aside
(remove if necessary).
- Disconnect crankshaft housing ventilation line from cylinder head
cover.
- Remove intake air duct between Mass Air Flow (MAF) sensor and
intake air elbow.
15-20
- Disconnect blue harness connector on Intake Manifold Tuning (IMT)

valve.
- Disconnect black harness connector for intake air temperature sensor
on resonator.
- Cut tie wraps and move wiring to side.
- Disconnect vacuum line at cruise control vacuum diaphragm and at
vacuum booster.
- Unbolt cruise control vacuum diaphragm and unhook cruise control
vacuum diaphragm linkage at throttle body.
- Disconnect harness connector on throttle body and vacuum lines on
fuel pressure regulator.
- Disconnect harness connectors from camshaft adjustment valve and

from fuel injectors (arrows).
- Disconnect harness connectors from Engine Coolant Temperature
(ECT) sensor and Camshaft Position (CMP) sensor (arrows).
- Cut tie wraps on valve cover.
- Unclip wiring retainer on fuel rail and disconnect crankshaft housing
ventilation lines from left and right-side valve covers. Move hoses and
wiring clear (to rear).
15-21
- Disconnect harness connector for tank diagnostic system in engine

compartment at arrow.
- Remove 4 bolts for fuel rail on intake manifold.
- Unclip fuel supply and return lines from retainer.
- Move fuel rail together with fuel injectors aside. Cover fuel injectors
with clean cloth.
- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove camshaft gear using T40001 special tool.

- Disconnect left-side spark plug connectors.
- Unbolt bracket for ignition coils (4 bolts) and move to right side together
with ignition coils.
- Unhook accelerator pedal cable and pull up out of retaining bracket.
15-22
- Disconnect vacuum line at throttle body and line between vacuum

booster and intake air elbow (arrows).
- Remove intake air elbow.
- Remove intake manifold.
- Disconnect heated oxygen sensor harness connector at left-side of
heater core and set aside.
- Remove left-rear toothed belt guard (arrows).

- Unbolt coolant hose at rear of cylinder head.
15-23
- Unbolt coolant hose at front of cylinder head (arrows).

- Using 3452 polydrive special tool, loosen cylinder head bolts in reverse
order of tightening sequence and remove.
- When removing and installing, use 3452 polydrive together with

normal commercial 10 mm socket.
15-24
Installing
Notes:
Bolt holes in engine block for cylinder head

bolts must be free of oil and coolant.
Always replace cylinder head bolts.
Vacuum line connections page 10-23
- Install centering pin for intake manifold.
- Replacement cylinder head may be used to

replace left or right cylinder head. Install sealing
cap at appropriate front end of replacement
cylinder head.
- Coat lip of sealing cap with sealant AMV 188

001 02.
- Using VW295 needle bearing drift press in sealing cap until lip of cap
seals with chamfer end of cylinder head.
- Before installing cylinder head, set crankshaft and camshafts to TDC
for cylinder 3.
- Install cylinder head gasket onto guide sleeves. Marking "oben" or Part
No. must face toward cylinder head.
- Install cylinder head, install cylinder head bolts and tighten hand-tight.
15-25

follows:
Stage 1: 60 Nm (44 ft lb)
Stage 2: additional 1/2 turn (180 ) using rigid wrench (in two 1/4 turns
(90 ) if necessary).
It is not necessary to re-torque cylinder head bolts again after repairs

Sealing contact surfaces between bearing cap and cylinder head.
- Carefully apply small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head using small screwdriver.
15-26
Tightening torques
torque
Bolts M6 10 Nm (7 ft lb)
Bolts M8 20 Nm (15 ft lb)
Camshaft bearing cap and 10 Nm (7 ft lb)
camshaft adjuster
Exhaust manifold to cylinder 25 Nm (18 ft lb)
head
Front exhaust pipe to exhaust 25 Nm (18 ft lb)
manifold
Heated Oxygen Sensor 50 Nm (37 ft lb)
(HO2S)
Spark plugs 25 Nm (18 ft lb)
Toothed belt sprocket to 55 Nm (41 ft lb)
camshaft
Intake manifold to cylinder 10 Nm (7 ft lb)
head
Cylinder head cover 10 Nm (7 ft lb)
15-27
Cylinder head, checking for distortion
- Measure at several points using straight-edge.

Maximum permissible distortion: 0.1 mm (0.004 in.)
15-28
Cylinder head, resurfacing
Resurfacing of the cylinder head is only permissable up to minimum

dimension -a-.
Dimension -a-: 139.25 mm (5.4823 in.).
15-29
Test conditions
Engine oil temperature at least 30 C
Battery fully charged
- Disconnect harness connectors from all 6 fuel

injectors.
- Disconnect 5-pin harness connector from power

output stage of ignition coils.
- Open throttle fully.
- Use VAG1381 or VAG1763 compression tester

to check compression.
- Operate starter until no further pressure

increases are indicated by VAG1381 or
VAG1763 compression tester.
Compression pressure
New Wear Max. permissable

limit difference between
cylinders
9-14 bar 7.5 bar 3 bar (44 psi)

(131-203 (109 psi)
psi)
15-30
Sealing cap (core plug) in cylinder head,

installing
Cylinder heads supplied as replacement parts

can be used on either the left or right-sides of the
engine. A sealing cap (core plug) must be
installed in the front end of the cylinder head in
each case.

CAUTION!
Part numbers are listed here for reference

only. Always check with your Parts
department for the latest information.
- Using VW295 needle bearing drift, drive in sealing cap (core plug) until
outside rim is flush with end of chamfer in cylinder head (see inset).
15-31
Camshafts and camshaft adjusters,

Removing


Left-side cylinder head
- Unbolt engine coolant expansion tank from bracket and lay aside.
- Remove crankshaft housing ventilation line from valve cover.
15-32
Right-side cylinder head
- Remove intake air duct between Mass Air Flow (MAF) sensor and
intake air elbow.
- Disconnect EVAP canister purge regulator valve and remove valve
from retainer.
- Disconnect harness connector for mass air flow sensor.
- Turn connection pipe for secondary air injection pump on air cleaner
45 in clockwise direction and pull forward off air cleaner.
- Unbolt air cleaner and remove.
15-33
All models
- Remove Camshaft Position (CMP) sensor

housing and shutter wheel.
- Unbolt shutter wheel for Camshaft Position

(CMP) sensor -G40- and carefully pry out using
screwdriver.
Tightening torque: 20Nm (15 ft lb)
- Install 3391 camshaft locator bar into camshaft

locking plates.
- Loosen both bolts for camshafts and back out

bolts approx. 5 turns.
- Remove both camshaft sprockets using T40001 special tool.

- Using screwdriver, carefully lift out oil lines for camshaft bearing
lubrication from camshaft bearings.
When lifting out oil lines, be careful not to damage positioning clips.
15-34
- Secure camshaft adjuster with 3366 bracket tensioner.
Note:
If the bracket tensioner is tightened too far, the camshaft adjuster may be
damaged.
- Verify that camshafts are at TDC.

Both camshaft markings must align with arrows on bearing caps.
- Clean camshaft drive chain and camshaft chain gears opposite both
arrows on bearing caps. Mark installed position with paint.
15-35
The distance between the two arrows/paint marks is equivalent to 16 drive

chain rollers.
The notch on the exhaust camshaft is slightly offset inward toward chain
roller -1-.
Note:
Do not mark chain using punch, filing a notch or similar.
- Remove camshaft adjuster retaining bolts.

- Remove bearing caps -1-,-3-,-5- and -7- and lay on a clean surface in
correct order.
- Alternating in diagonal sequence, loosen bearing caps -2- and -4- of
intake and exhaust camshafts and remove.
- Remove both camshafts together with camshaft adjuster.
15-36
Installing
- Replace rubber/metal camshaft adjuster gasket and spread thin layer

of sealant D 454 300 A2 on hatched surface.
- Install drive chain on camshaft chain gear as follows:
- When installing the old drive chain, line up paint markings (arrows).
15-37
If a new drive chain is installed, distance between notches -A- and -B- on
camshafts must equal the distance between 16 drive chain rollers.
Illustration shows where first and sixteenth drive chain rollers must be
installed on chain gears.
Note:
Notch -A- is slightly offset inward toward drive chain roller -1-.
- Slide in camshaft adjuster between drive chain (second technician

required).
- Install camshafts with drive chain and camshaft adjuster into cylinder
head.
- Oil camshaft journal surface.
Notes:
Alignment bushings for bearing caps and camshaft adjuster must be
installed in cylinder head.
When installing bearing caps, verify marking on cap is readable from
intake side of cylinder head.
- Tighten camshaft adjuster (pay attention to alignment bushings).
- Tighten bearing caps -2- and -4- in alternating diagonal sequence (pay
attention to alignment bushings).
- Install both bearing caps on chain sprockets of intake and exhaust
camshafts.
15-38
- Verify correct position of both camshafts.
Both camshaft markings must align with arrows on bearing caps

(arrows).
The distance between the two arrows/paint markings is equivalent to 16

drive chain rollers.
Note:
The notch on exhaust camshaft is slightly offset inward toward drive chain
roller -1-.
15-39
- Lightly coat hatched surface of double bearing cap -1- and bearing cap
-7-...
- ...with sealant D 454 300 A2 and install bearing cap (pay attention to
alignment bushings).
- Install the other bearing caps (pay attention to alignment bushings).
- Replace oil lines for camshaft bearing lubrication and install.
- Replace oil seal for intake and exhaust camshafts page 15-14 .
- Remove 3366 bracket tensioner.
15-40
CAUTION!
After installing new hydraulic lifters, the

engine must not be started for approx. 30
minutes. The hydraulic valve lifters have to
settle (otherwise valves will strike the
pistons).
After installing the valvetrain and lifters,

carefully rotate the crankshaft by hand at
least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
Sealing contact surfaces between bearing cap and cylinder head.
- Carefully apply a small amount of sealant D 454 300 A2 at four end

points of sealing surfaces on cylinder head (arrows) using small screw
driver.
- Install cylinder head cover.
- Install toothed belt page 13-15 .
15-41
Tightening torques
torque
Bolts M6 10 Nm (7 ft
lb)
M8 20 Nm (15 ft
lb)
Except for the following:
Bearing cap to cylinder 10 Nm (7 ft
head lb)
Camshaft adjuster to cylinder 10 Nm (7 ft
head lb)
Shutter wheel for Camshaft 25 Nm (18 ft
Position (CMP) sensor -G40- to lb)
camshaft
Housing for Camshaft Position 10 Nm (7 ft
(CMP) sensor -G40- to cylinder lb)
head
Camshaft gear to 55 Nm (41 ft
camshaft lb)
Camshaft bearing cap and 10 Nm (7 ft
camshaft adjuster lb)
Cylinder head cover 10 Nm (7 ft
lb)
15-42
Camshaft axial play, checking
- Remove camshafts page 15-31 .
- Remove hydraulic valve lifters.
- Install camshafts without chain into cylinder

head and tighten with bearing caps 2 and 4.
- Secure VW387 dial indicator holder with dial indicator to cylinder head.
- Press camshaft by hand against dial indicator.
- Set dial indicator to zero.
- Press crankshaft away from dial indicator.
- Read clearance.
New Wear limit

0.05-0.15 mm (0.0020-0.0059 in.) 0.20 mm (0.0079 in.)
15-43
Valve dimensions
WARNING!
Valves must not be refaced by cutting or grinding.

Only hand lapping is permitted.
Dimension Intake valve Exhaust valve

Diameter -a- 26.8 - 27.0 mm 29.8 - 30.0 mm
(1.055 - 1.063 in.) (1.173 - 1.181 in.)

Diameter -b- 5.96 - 5.97 mm 5.94 - 5.95 mm
(.2346 - .2350 in.) (.2338 - .2342 in.)

Length -c- 104.84 - 105.34 mm 103.64 - 104.14 mm
(4.1275 - 4.1472 in.) (4.0803 - 4.0999 in.)

Angle -a- 45 45
15-44
WARNING!
Sodium-filled exhaust valves must not be

scrapped without first being properly treated.
The valves must be cut open using a

hacksaw, by hand, between the valve head
and the middle of the stem.
The valves must not come into any contact

with water while being cut.
After cutting open the valves, throw not more

than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.
Valves that have been treated in this way can

be disposed of as normal waste.
15-45
Hydraulic valve lifters, checking
CAUTION!
After installing new hydraulic valve lifters the

engine must not be started for about 30
minutes. The hydraulic valve lifters must
settle (otherwise valves will strike pistons).
Then turn crankshaft two full revolutions by
hand before starting.
Notes:
Only replace hydraulic valve lifters in complete

sets. Hydraulic valve lifters cannot be adjusted
or repaired.
Irregular valve noise when starting engine is

normal.
- Start engine and let run until coolant

temperature reaches at least 80 C.
- Increase RPM to 2500 for about 2 minutes. If

necessary, test drive vehicle.
If hydraulic valve lifters are still loud, locate faulty

valve lifter as follows:
- Rotate crankshaft clockwise by turning mounting

bolt for toothed belt sprocket until lobes on
camshaft of hydraulic valve lifters to be checked
are pointing upward.
- Measure clearance between cam and valve

lifter.
15-46
- Push down on valve lifters using wood or plastic wedge. If 0.20 mm

(0.008 in.) feeler gauge can be inserted between camshaft and valve
lifter, replace valve lifter.
Note:
If irregular valve noise occurs repeatedly during short journeys and

disappears after extended driving, the oil check valves must be replaced
page 17-9 .
15-47
Valve stem oil seals, replacing
- Remove camshafts page 15-31 .
- Remove valve lifters (do not interchange) and

lay aside with contact surface facing down.
- Remove spark plugs.
- Move piston for individual cylinder to Bottom

Dead Center (BDC) position.
Note:
Lightly tap valve lever to loosen stuck valve

keepers.
Exhaust side
Note:
Before attaching the adjustable rod, remove the

two studs in the center of the cylinder head and
the three upper studs (intake side) for mounting
the cylinder head cover.
- Install VW653/3 pressure hose together with

seal hand tight into spark plug hole of relevant
cylinder and apply constant pressure (at least 6
bar).
15-48
- Attach 2036 adjustable rod (as shown in figure) using M6 x 40 bolts

with large washers.
- Remove valve spring using VW541/1 lever and VW541/5 valve spring
tensioner.
- Remove valve spring and valve spring plate.
- Remove valve stem oil seal using 3047A slide hammer.
- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3129
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
15-49
Intake side
Note:
The intake valves are installed in the cylinder

head at different angles.
3362 valve spring tool can be used in two different positions:
1 - Upper position for center valve

2 - Lower position for two outer valves
3 - Threaded holes on each side to take M6 x 25 bolts for mounting valve
spring tool to cylinder head.
- Attach 3362 valve spring tool to cylinder head using two bolts supplied
(as shown in figure).
- Screw VW653/3 pressure hose together with seal hand tight into spark
plug hole of relevant cylinder and apply constant pressure (at least 6
bar).
- Set position of valve spring tool for relevant valve and remove valve
spring using threaded spindle.
15-50
- Remove valve stem oil seal using 3364 valve seat tool.
- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3365
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
15-51
Valves, refacing
WARNING!
Valves must not be refaced by cutting or

grinding.
Only hand lapping is permitted.
Observe the WARNING regarding proper

disposal of sodium-filled exhaust valves
page 15-44 .
15-52
Valve guides, checking
When servicing engines or cylinder heads with

leaking valves, refacing or replacing valve seats
and valves is not sufficient. Valve guides must be
checked for wear. This is especially important for
engines with high mileage.
- Insert valve into guide.

Valve shaft edge must seal with guide. Due to differences in valve stem
diameter, make sure only intake valves are used to check intake
guides, and only exhaust valves are used to check exhaust guides.
- Measure axial play.
Wear limit
Intake valve guide Exhaust valve guide

0.8 mm (0.031 in.) 0.8 mm (0.031 in.)
- If wear limit is exceeded, replace cylinder head.
15-53
Valve seats, refacing
Notes:
Only reface valve seats enough until a perfect

contact pattern is obtained.
Before refacing, calculate the maximum

refacing dimension.
If refaced dimension is exceeded, hydraulic

valve lifter function is no longer guaranteed and
cylinder head must be replaced.
Calculating maximum allowable refacing

dimension
- Insert valve and press firmly against valve

seat.
Note:
If valve is replaced during repair, use a new

valve for measurement.
- Measure distance between end of valve stem and top surface of

cylinder head (four-valve head shown).
- Calculate maximum allowable refacing dimension using distance
measured and minimum dimension.
15-54
Minimum dimensions
Outer intake Center intake Exhaust valve
valve valve
32.2 mm 33.2 mm 33.0 mm (1.299
(1.268 in.) (1.307 in.) in.)
The measured distance minus the minimum

dimension equals the maximum permissible
refacing dimension.
Example
Outer intake valve
Measured distance 33.0 mm (1.299
in.)
Minimum dimension - 32.2 mm (1.268
in.)
Maximum permissible refacing = 0.8 mm (0.031
dimension in.)
Note:
If the measured distance is less than the

minimum dimension, repeat the measurement
with new valves, or replace the cylinder head.

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Code Control Module (function 07) Page 1 of 3

Code Control Module

Rapid data transfer HELP When indicated on display

Code Control Module Q When indicated on display

1) LEV: Abbreviation for Low Emission Vehicle

2)ASR/ESP: Abbreviation for Anti-Slip

- Confirm input using the -Q- button.

Rapid data transfer HELP Indicated on display (function selection)

Country / Exhaust 07 USA LEV (emissions regulation)

During a test sequence which must be performed

When the readiness code is generated after a

If a single test is completed entirely, but indicated

Readiness code is returned to"0 1 1 0 1 1 0 1"

DTC memory was erased,

Voltage supply to ECM was cut off (e.g.

a new Engine Control Module (ECM) was

In this case, the readiness code must be re-

During driving operation in various load

Read readiness code

- Connect VAS5051 tester or VAG1551 scan tool

Rapid data transfer HELP When indicated on display

Read measuring value block Q When indicated on display

Read Measuring Value Block 86 When indicated on display

0 = completed 0 = completed 0 = completed

Note for display field 1:

X X X X X X X X Notes for display group 086, display field 1

Indication 0 = test was performed

Indication 0 = test was performed

Secondary air system

Indication 0 = test was performed

Indication 0 = test was performed

Oxygen sensor heating

Indication 0 = test was performed

Once the specified value "0 0 0 0 0 0 0 0" is

Rapid data transfer HELP Indicated on display (function selection)

If specified value is not obtained:

- Generate readiness code Page 01-73 .

Readiness code, generating

Special Tools and Equipment

VAG1788/10 RPM adjuster

Vehicles with automatic transmission Selector lever in P or N.

Coolant temperature at least 80 C Display group 004, display field

Work step 1: Check DTC Memory

Engine not running, ignition switched on.

- Connect VAS5051 tester or VAG1551 scan tool

Rapid data transfer HELP When indicated on display

If no DTCs are stored:

Work step 2: Erase DTC Memory

Engine not running, ignition switched on.

Rapid data transfer HELP When indicated on display

Rapid data transfer When indicated on display

Work step 3: Adapt throttle valve control

Engine not running, ignition switched on.

Rapid data transfer HELP When indicated on display

Basic Setting Q When indicated on display

System in basic setting 60 When indicated on display

If specified value is not

Note for display field 3:

4 indicates the specification "ADP OK" after adaptation.