Fuel Injectionn

2000 Audi TT
2000-2004 ENGINE PERFORMANCE Multiport Fuel Injection (MFI), 1.8L Turbo, ATC - TT
2000-2004 ENGINE PERFORMANCE
Multiport Fuel Injection (MFI), 1.8L Turbo, ATC - TT
MULTIPORT FUEL INJECTION (MFI)

MOTRONIC MULTIPORT FUEL INJECTION AND IGNITION SYSTEM, REPAIRING
Scan Tool (ST) and test equipment safety precautions
To reduce the risk of personal injury and/or damage to the fuel injection and ignition systems, always observe
the following:
z Always switch off ignition before disconnecting or connecting lines of the fuel injection and ignition
system, including test leads.
z If engine is to be cranked at starting RPM without starting (for example, for compression testing),
disconnect connectors from ignition coils and from fuel injectors.
z It is possible that a 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.
z Always switch ignition off before cleaning engine.
z Always switch ignition off before disconnecting or connecting battery. Failure to do so may damage the
Engine Control Module (ECM).
If special testing equipment is required during road test, note the following:
WARNING: z Due to weight, size and need for manual operation of test
instruments while vehicle is driven on public roads, instrument must
be used only with a Driver operating the vehicle and an Instrument
Operator operating the test equipment.
z Do not use Instrument with Driver only. Always use two persons to
conduct test.
z Do not place Instrument on lap of Driver or front seat passenger
because emergency stop may dislodge Instrument and cause airbag
deployment with risk of injury to Instrument Operator.
WARNING: Use of Instrument in Audi TT Coupe:
z Place Instrument in rear seating area and secure by available safety

belt.
z Instrument Operator must be seated in the other rear seating
position, after sliding front passenger seat and moving the seat back
as far forward as possible. Do not activate the seat back release
lever.
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2000 Audi TT
z Instrument Operator must wear safety belt.
Use of Instrument in Audi TT Roadster:
z Use only Instrument VAG 1551 Scan Tool (ST). DO NOT USE VAS
5051.
z Before test, deactivate passenger's airbag using key operated
switch in glove compartment or via OBD program.
z Instrument Operator must be seated on passenger seat with safety
belt worn.
z Place Instrument in foot well in front of passenger seat in a manner
allowing the Operator to use the Instrument in a safe manner.
z After completion of test, re-activate front passenger airbag.
Rules of cleanliness
When working on the fuel supply/injection system, pay careful attention to the following rules of cleanliness:
z Thoroughly clean all connections and the surrounding area before disconnecting.
z Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
z Carefully cover over opened components or seal, if repairs are not carried out immediately.
z Only install clean components: Only unpack replacement parts immediately prior to installation. Do not
use parts that have been stored loose (in tool boxes etc.).
z When the system is open: Do not work with compressed air if it can be avoided. Do not move vehicle
unless absolutely necessary.
z Disconnected electrical harness connectors must be protect from dirt and moisture
z Make sure harness connectors are dry before connecting.
Technical data
TECHNICAL DATA
Engine identification ATC (1.8L/5V/Turbo 132 kW -engine)
Idle speed 800 - 920 RPM (manual transmission, Front Wheel
Engine speed cannot be adjusted, it is regulated by Drive -FWD-)
idle stabilization 720 - 840 RPM (manual transmission, All Wheel
Drive -AWD-)
640 - 760 RPM (automatic transmission, Front
Wheel Drive -FWD-)
Engine speed (RPM) limitation approx. 6800 RPM
via fuel injector shut-off
Fuel pressure at idle Vacuum hose connected approx. 2.5 bar positive pressure
speed Vacuum hose disconnected approx. 3.0 bar positive pressure
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2000 Audi TT
Residual pressure after 10 min. minimum 1.5 bar positive pressure

Fuel injectors Injection stream Dual-hole nozzle / same for all injectors
Injection quantity (30 s) 145 +/- 12 ml
Resistance (room 12 - 13 ohm
temperature)
Spark plugs Replacement Part No. 101 000 063 AA (NGK)
Manufacturer code PFR6Q (NGK)
Component locations, overview
The following list pertains to Fig. 1 .
1. - Leak Detection Pump (LDP) - V144-

z Below wheel housing, front, left
2. - Bank 1 sensor 1 (oxygen sensor before catalytic converter), with oxygen sensor heating; Bank 2
sensor 2 (oxygen sensor behind catalytic converter), with oxygen sensor heating;
z Both oxygen sensors and their related harness connectors are accessible from below after vehicle is
raised
z Component location of oxygen sensors, see OXYGEN SENSORS AND PROTECTIVE COVER
z Component location of harness connectors for oxygen sensors, see BLACK AND BROWN
CONNECTORS
3. - Camshaft Position (CMP) sensor 2 -G163 -
4. - Fuel injectors -N30 through N33-
5. - Motronic Engine Control Module (ECM) -J220-
6. - Ignition coils -N-, -N128-, - N158-, -N163-
7. - Wastegate Bypass Regulator Valve -N75-
z Checking:
See CHARGE AIR PRESSURE CONTROL VALVE -N75-, TESTING .
8. - Throttle Position (TP) sensor-G79- and sender -2- for accelerator pedal position -G185-
z Component location, see COMPONENT LOCATIONS OF THROTTLE POSITION (TP)
SENSOR -G79- AND SENDER 2 FOR ACCELERATOR PEDAL POSITION -G185-
9. - Brake light switch -F- and brake pedal switch -F47 -
z Component location, see COMPONENT LOCATION BRAKE LIGHT SWITCH -F- AND
BRAKE PEDAL SWITCH -F47-
10. - Clutch vacuum vent valve switch -F36 -
z Component location, see COMPONENT LOCATION, CLUTCH VACUUM VENT VALVE
SWITCH -F36-
11. - Exhaust warning lamp -K83-
z Component location, see COMPONENT LOCATION, EXHAUST WARNING LAMP -K83- .
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12. - Malfunction light for power accelerator activation -K132-

z "EPC" warning lamp
z Component location, see COMPONENT LOCATION, MALFUNCTION LIGHT FOR

POWER ACCELERATOR ACTIVATION -K132-
13. - Secondary Air Injection (AIR) pump relay -J299-
z Under a black, synthetic cover; directly behind Mass Air Flow (MAF) sensor
14. - Mass Air Flow (MAF) sensor -G70-

15. - Engine Coolant Temperature (ECT) sensor -G62-
16. - Fuel pressure regulator
17. - Speedometer Vehicle Speed Sensor (VSS) -G28-
18. - Knock Sensor (KS) 2 -G66-
19. - Turbocharger boost pressure recirculation valve -N249-
20. - 3-pin harness connector
z pieces
z Component location, see COMPONENT LOCATION, 3-PIN HARNESS CONNECTORS
z For Knock Sensor (KS) 1 - G61-
z For Engine Speed (RPM) sensor -G28-
z For Knock Sensor (KS) 2 - G66-
21. - Secondary Air Injection (AIR) solenoid valve -N112-

22. - Knock Sensor (KS) 1 -G61-
23. - Intake Air Temperature (IAT) sensor -G42-
24. - Secondary Air Injection (AIR) pump motor -V101-
z Checking:
See SECONDARY AIR SYSTEM, COMPONENTS AND FUNCTION .
25. - Pressure switch/power steering -F88 -

z Component location, see COMPONENT LOCATION, PRESSURE SWITCH/POWER
STEERING -F88-
26. - Throttle valve control module -J338 -
z With throttle drive (power accelerator actuation) -G186 -, angle sensor -1- for throttle drive (power
accelerator actuation) -G187- and angle sensor -2- for throttle drive (power accelerator actuation) -
G188-
27. - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-
28. - Charge air pressure sensor - G31-
z Component location: Screwed in, above in charge air cooler
z Checking:
See CHARGE AIR PRESSURE SENSOR -G31-, TESTING .

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z Headlight must be removed in order to access charge air pressure sensor.
See HEADLIGHTS or HEADLIGHTS WITH HIGH INTENSITY GAS DISCHARGE (HID)

LAMPS .
Fig. 1: Identifying Multiport Fuel Injection (MFI) Component Locations

Courtesy of AUDI OF AMERICA, INC.
Oxygen sensors and protective cover
Item 1 : Bank 1 sensor 1 (oxygen sensor before catalytic converter) with oxygen sensor heating
Item 2 : Protective cover of oxygen sensor connector for both oxygen sensors
Item 3 : Bank 1 sensor 2 (oxygen sensor behind catalytic converter) with oxygen sensor heating
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4-pin harness connectors for both oxygen sensors and oxygen sensor heating are accessible at vehicle floor after
unscrewing protective cover (arrows).
Fig. 2: Identifying Oxygen Sensors And Protective Cover

Black and brown connectors
Black connector: Harness connector for bank 1 sensor 1 (oxygen sensor before catalytic converter) and
oxygen sensor heating
Brown connector: Harness connector for bank 1 sensor 2 (oxygen sensor behind catalytic converter) and
oxygen sensor heating
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Fig. 3: Locating Black And Brown HO2S Connectors

Component locations of Throttle Position (TP) sensor -G79- and sender 2 for accelerator pedal position -G185-
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Fig. 4: Locating Component Locations Of Throttle Position (Tp) Sensor -G79- And Sender Accelerator
Pedal Position -G185 -
Component location brake light switch -F- and brake pedal switch -F47-
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Fig. 5: Locating Component Location Brake Light Switch -F and Brake Pedal Switch -F47 -
Component location, exhaust warning lamp -K83-
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Fig. 6: Exhaust Warning Lamp - K83- (MIL)

Component location, malfunction light for power accelerator activation -K132-
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Fig. 7: Malfunction Light For Power Accelerator Activation -K132-

Component location, clutch vacuum vent valve switch -F36-
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Fig. 8: Locating Clutch Vacuum Vent Valve Switch -F36 -

Component location, 3-pin harness connectors
1. - For Knock Sensor (KS) 1 -G61-

2. - For speedometer Vehicle Speed Sensor (VSS) -G28-
3. - For Knock Sensor (KS) 2 -G66-
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Fig. 9: 3 -Pin Harness ConnectorLocations

Component location, pressure switch/power steering -F88-
Fig. 10: Locating Pressure Switch/Power Steering -F88 -

Air filter, disassembling and assembling
1. - Seal
3. - Phillips-head screw
4. - Air guide
5. - 5-pin harness connector
6. - Phillips-head screw
7. - Air filter, upper portion
8. - Filter element
9. - Nut -10 Nm
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10. - Air intake connection

11. - Air filter, lower portion
12. - Hex-bolt (10 Nm)
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Fig. 11: Exploded View Of Air Filter Assembly

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Wire and component test using VAG1598/31 test box
z If the Engine Control Module (ECM) is equipped with a metal anti -theft housing (for theft prevention),
the metal anti-theft housing must be removed from the ECM to connect the test box. See ENGINE
CONTROL MODULE (ECM) (WITH METAL ANTI-THEFT HOUSING), REPLACING . After
repairs are complete, the metal anti -theft housing must be reinstalled.
z VAG1598/31 test box is designed so that it can be simultaneously connected to the wiring harness at the
Engine Control Module (ECM) and also to the ECM itself.
z This is advantageous because electronic engine control remains fully functional (e.g. measurement of
signals with engine running) when the test box is attached.
z Relevant test procedures note whether Engine Control Module (ECM) should also be connected to the
test box or not.
z Always use VAG1594A connector test kit to attach measurement devices (for example, VAG1527B
voltage tester, VAG1526 multimeter etc.).
Special tools and equipment
z VAG1598/31
Fig. 12: Identifying Special Tools And Equipment

VAG1598/31 test box
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WARNING: To reduce the risk of damage to electronic components, switch on power

to components before connecting test leads and observe test
requirements.
z Switch ignition off.

z Remove windshield wiper arms (unscrew).
z Disconnect cover for plenum chamber and place it on windshield side.
z Disengage locking lugs and remove control module connector.
z Connect VAG1598/31 test box to connector of wiring harness. Ground clip (arrow) at test box must be
clipped to battery negative terminal. Relevant test procedures note whether Engine Control Module
(ECM) should also be connected to the test box.
Fig. 13: Connecting VAG1598/31 Test Box To Connector Of Wiring Harness

z Perform test as described in relevant repair sequence.
Perform the following work after re -connecting Engine Control Module (ECM):
z Check DTC memory and erase it if necessary. See DIAGNOSTIC TROUBLE CODE (DTC)
MEMORY, CHECKING AND ERASING .
z Generate readiness code. See READINESS CODE, GENERATING .
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All models
NOTE: In the first adaptation phase during engine Basic Setting, it is possible that the
idle will be rough and vehicle may shake slightly in drive mode.
Procedure after voltage supply is interrupted
NOTE: In the first adaptation phase during engine Basic Setting, it is possible that the
idle will be rough and vehicle may shake slightly in drive mode.
Special tools and shop equipment
z VAS5051 with VAG5051/1
or
Fig. 14: Identifying Special Tools - VAS5051

z VAG1551 with VAG1551/3B
Procedure
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Perform the following steps after an interruption in the voltage supply.
Engine Control Module (ECM) (without metal anti-theft housing), replacing
Removing ECMs with metal anti -theft housing. See ENGINE CONTROL MODULE (ECM) (WITH
METAL ANTI-THEFT HOUSING), REPLACING .
NOTE: Adaptation values are erased when connector is disconnected from the Engine
Control Module (ECM), DTC memory content remains intact.
Removing Engine Control Module (ECM)
z Connect VAS5051 tester or VAG1551 scan tool and select control module for engine electronics using
"address word" 01. See VAS5051 VEHICLE DIAGNOSTIC, TESTING AND INFORMATION
SYSTEM OR VAG1551 SCAN TOOL, CONNECTING AND SELECTING FUNCTIONS .
Ignition must remain switched on for this.
VAG1551 Scan Tool display indicates control module identification (example)
Fig. 15: VAG1551 Scan Tool Display - Control Module Identification

z First (and always) allow display of control module identification and print it out. See PROCEDURE .
z Compare coding with coding versions. See CODING TABLE .
z Remove windshield wiper arms (unscrew).
z Disconnect cover for plenum chamber and place it on windshield side.
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z Use a screwdriver to press locking lugs of bracket to the side and then remove Engine Control Module
(ECM) toward front.
Fig. 16: Pressing Locking Lugs Of Bracket To Side Using Screwdriver

z Disengage locking lugs and remove control module connector.
Installing Engine Control Module (ECM)
Installation is in reverse order of removal, noting the following:
NOTE: In the first adaptation phase during engine Basic Setting, it is possible that idle
will be rough and vehicle may shake slightly in drive mode.
NOTE: Important!
After installing a new Engine Control Module (ECM), the following work steps must be performed:
z Observe notes for coding new Engine Control Module (ECM). See CODE CONTROL MODULE .
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z Perform adaptation of throttle valve control module -J338-. See THROTTLE VALVE CONTROL
MODULE, ADAPTATION .
z For vehicles with automatic transmission, position of pedal value sensor for kick down must be learned.
See KICK DOWN FUNCTION, LEARNING .
z Cruise control must be switched off at ECM (if equipped - identify at steering column).
See CRUISE CONTROL SYSTEM (CCS), ON BOARD DIAGNOSIS .
Engine Control Module (ECM) (with metal anti-theft housing), replacing
Removing ECMs without metal anti -theft housing, see ENGINE CONTROL MODULE (ECM)
(WITHOUT METAL ANTI-THEFT HOUSING), REPLACING .
NOTE: Adaptation values are erased when the harness connector is disconnected from
the Engine Control Module (ECM), the DTC memory content remains intact.
Remove Engine Control Module (ECM)
Removing
z Connect VAS5051 tester and select vehicle system "01 - Engine Electronics". Ignition must be switched
on for this.
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Fig. 17: VAS5051 Scan Tool Display - Engine Electronics

VAS5051 tester display will indicate the control module identification and coding -2-.
z Always allow display of control module identification first and print it out.
z Pry off both caps at wiper arms using a screwdriver.
z Loosen hex -nuts (arrows) several turns. See Fig. 18 .
z Loosen wiper arms -1- from wiper axle by lightly tilting. See Fig. 18 .
z Remove hex nuts completely and remove wiper arms.
z Remove plenum chamber cover rubber seal -2-. See Fig. 18 .
z Remove plenum chamber cover -3- and place it on windshield side.
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Fig. 18: Removing Plenum Chamber Cover

NOTE: Item -1- in illustration shows the Engine Control Module (ECM) with anti-theft
housing.
z Use a screwdriver to press locking lug of bracket (arrow) to the side and then remove Engine Control
Module (ECM) toward front.
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Fig. 19: Removing Engine Control Module (ECM)

To restrict accessibility (for theft prevention) to the harness connectors and Engine Control Module (ECM), the
Engine Control Module (ECM) -1- is screwed to a metal anti-theft housing -4- via a locking mechanism -2- and
snap-off screws -3-.
The threads of the snap -off screws are coated with locking compound to make it more difficult to remove the
snap -off screws.
To disconnect the harness connectors from the Engine Control Module (ECM) (for example, when connecting a
test box or when replacing the ECM), the ECM must be removed from the metal anti-theft housing. This
procedure is described as follows.
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Fig. 20: Engine Control Module With Metal Anti-Theft Housing

The following equipment is required:
z Heat gun -1- (from VAS1978 Wiring Harness Repair Kit)
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Fig. 21: Identifying Heat Gun And Adapter Nozzle

z Adapter nozzle -2- (also from VAS1978 Wiring Harness Repair Kit)
z Standard locking pliers
Procedure:
WARNING: The following work steps must be adhered to exactly to avoid damage
(burning) of wires, harness connectors, insulation and control modules!
Observe operating instructions of heat gun.
z "Flip" the Engine Control Module (ECM) with anti -theft housing in direction of the engine compartment
so that the locking mechanism (item -2- in illustration) becomes visible and place a clean rag below the
Engine Control Module (ECM) with anti -theft housing.
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Fig. 22: Identifying ECM Components (With Metal Anti-Theft Housing)

z Adjust the heat gun as shown in illustration, i.e. temperature adjustment -2- to maximum heat output and
the two -stage switch for air mass -3- to position 3.
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Fig. 23: Adjusting Heat Gun

NOTE: Next, use the heat gun to heat the threads of the locking mechanism in which
the snap -off screws are screwed into. This step loosens the locking compound
on the threads of the snap-off screws for easier removal.
WARNING: By heating the locking mechanism threads, the snap - off screws and
parts of the metal anti -theft housing will also become very hot. Be careful
not get burned! If possible, also make sure that only the threads are no
parts in the vicinity become heated. If necessary, cover them.
z Guide nozzle -1- of heat gun to the locking mechanism threads so that the nozzle "encloses" the threads.
It is OK to let the nozzle make contact at the upper end of the metal anti -theft housing.
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Fig. 24: Guiding Nozzle Of Heat Gun To The Locking Mechanism Threads
z Switch on heat gun and heat up thread for approx. 20 to 25 seconds.

z Next, using locking pliers -1-, grab screw head -2- and remove snap-off screw by turning in direction of
arrow.
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Fig. 25: Removing Snap-Off Screw Using Locking Pliers

The procedure for the second snap-off screw is exactly the same. Be very careful since the control module
connector is in close proximity.
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Fig. 26: Guiding Nozzle Of Heat Gun To The Locking Mechanism Threads
z Guide nozzle -1- of the heat gun to the locking mechanism threads again so that the nozzle "encloses" the
threads. It is OK to let the nozzle make contact at the upper end of the metal anti -theft housing.
z Switch on heat gun and heat up threads for approx. 20 to 25 seconds.
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Fig. 27: Removing Snap-Off Screw Using Locking Pliers

z Next, using locking pliers -1-, grab screw head -2- and remove snap-off screw by turning in direction of
arrow.
The Engine Control Module (ECM) can now be removed from the metal anti-theft housing.
z Disengage connectors from Engine Control Module (ECM) and then disconnect connectors.
z Remove old Engine Control Module (ECM) and insert new one.
Installing Engine Control Module (ECM)
Installation is the reverse order of removal, noting the following:
After repairs are complete, the metal anti -theft housing must be reinstalled. Use new snap-off screws.
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z Bend back locking lug of bracket.
After installing a new Engine Control Module (ECM), the following work steps must be performed:
z Activate Engine Control Module (ECM) in "Guided Troubleshooting" below subject heading "Engine
Control Module (ECM), replacing".
Use VAS5051 tester to do so.
Idle speed, checking
or
Fig. 28: Identifying Special Tool VAS5051

Test conditions
z Exhaust system free of leaks
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z Engine coolant temperature less than 80 °C

z Electrical consumers switched off (radiator fan must NOT run during test)
z A/C switched off
z Pressure gauge not connected
z Vehicles with automatic transmission: selector lever in P or N
NOTE: z Idle speed cannot be adjusted.

z Idle speed is checked during Basic Setting of the engine.
z During Basic Setting, the Evaporative Emission (EVAP) canister purge
regulator valve (EVAP valve -N80-) is closed and the A/C compressor is
switched off.
Test sequence
z Check DTC memory. See DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING AND
ERASING . 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.
z Let engine continue to run at idle.
WARNING: Engine coolant fan must not come on during test.
When indicated on display:
Fig. 29: VAG 1551 Scan Tool Display - Idle Speed, Checking (1 Of 4)
z Press buttons -0- and -4- to select "Basic Setting" and press -Q- button to confirm input.
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z Press buttons -0-, -5- and -6- to select "display group number 056" and press -Q- button to confirm input.
Indicated on display:
z Check whether engine speed in display field 1 (actual engine speed) is within permitted tolerance range.
DISPLAY GROUP 56: IDLE STABILIZATION WITH ENGINE AT IDLE AND OPERATING
TEMPERATURE
Display fields
1 2 3 4
Display group 56: Idle stabilization with engine at idle and operating temperature
Display xxx /min xxx /min x.x % XXXXX
Indicated Engine speed (actual) Engine speed Idle control Operating conditions
(specified) torque change
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Specified 800 - 920 RPM(1) 860 RPM (1) x.x % 00000

value: 720 - 840 RPM (2) 780 RPM (2)
640 - 760 RPM (3) 700 RPM (3)

Note: If specified value is not Significance of numbers,
obtained, see TEST see TEST SEQUENCE
SEQUENCE
(1) Vehicles with Front Wheel Drive (FWD) and manual transmission
(2) Vehicles with All Wheel Drive (AWD) and manual transmission
(3) Vehicles with Front Wheel Drive (FWD) and automatic transmission
NOTE: z Engine speed in display field 1 (actual engine speed) is the current engine
speed.
z Engine speed in display field 2 (specified engine speed) is a theoretical
engine speed calculated by the ECM.
z At idle, the ECM always attempts to adapt the engine speed (actual) to the
specified engine speed (specified).
z This means that the engine speed (actual) must always approximately
match the engine speed (specified) at idle.
z Display fields 3 and 4 provide information, but are not relevant for
checking idle speed.
If specified value is obtained:
z Press -->button.
Indicated on display (function selection):
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If specified value is not obtained:
z Check DTC memory again. See DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING
AND ERASING .
z If DTC memory was erased, readiness code must be re-generated. See READINESS CODE,
GENERATING .
If idle speed is too high or low and there are no DTCs in DTC memory, the following tests (marked with
diamonds) must be performed
z Un-metered air in intake air system, checking. See INTAKE AIR SYSTEM, CHECKING FOR
LEAKS (UN-METERED AIR) .
z Check throttle valve control module. See THROTTLE VALVE CONTROL MODULE -J338-,
CHECKING .
z Evaporative Emission (EVAP) canister purge regulator valve always open, checking. See TANK
VENTILATION, CHECKING .
z Perform adaptation of throttle valve control module. See THROTTLE VALVE CONTROL
MODULE, ADAPTATION .
Significance of 5 digit display of display group 056
SIGNIFICANCE OF 5 DIGIT DISPLAY OF DISPLAY GROUP 056

x x x x x Display field 4
0 A/C compressor
0 = A/C compressor off
1 = A/C compressor on
0 Driving mode selected
0 = selector lever in P or N
1 = selector lever in 2/3/4/D/R
0 A/C readiness maximum heating/cooling power
0 Indication always 0
0 Power steering pressure
0 = no signal from pressure switch for power steering
1 = signal from pressure switch for power steering (steering fully turned to stop)
System pressure, fuel pressure regulator and residual pressure, checking
z VAG1318
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Fig. 33: Identifying Special Tool VAG1318

z VAG1318/7
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z VAG1318/17 (2x)
Fig. 34: Identifying Special Tool VAG1318/17

NOTE: Fuel pressure regulator regulates fuel pressure according to intake manifold
pressure. This ensures that the pressure drop at the fuel injectors remains the
same for each speed and load range of the engine.
Test conditions
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z Fuel Pump (FP) OK, checking. See FUEL PUMP (FP) RELAY -J17-, CHECKING ACTIVATION .
z Fuel Pump (FP) OK, checking:
See FUEL PUMP, ELECTRICAL TESTING .
z Fuel filter OK
z Battery voltage at least 11 V
WARNING: The fuel system is under pressure. When opening the system, place a rag
around connections then release pressure by carefully prying open
connection
Checking system pressure
z Open fuel filler flap briefly (release pressure).

z Remove fuel supply hose -1- (with white marking) from supply line.
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Fig. 35: Removing Fuel Supply Hose From Supply Line

z Connect VAG1318 using adapters 1318/7 and 1318/17 (2 pieces) at supply line.
Fig. 36: Connecting VAG1318 At Supply Line

z Open valve of pressure gauge. Lever points in direction of flow.

z Start engine and let run at idle.
z Measure fuel pressure.
z Specified value: approx. 2.5 bar positive pressure
z Disconnect vacuum hose at fuel pressure regulator.
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Fig. 37: Disconnecting Vacuum Hose At Fuel Pressure Regulator

z Fuel pressure must rise to approx. 3.0 bar positive pressure.

z Check for proper seal and residual pressure by observing pressure drop on pressure gauge.
z After 10 minutes, there must be at least 1.5 bar positive pressure
If residual pressure sinks below 1.5 bar positive pressure:

z Switch ignition off after pressure has built up. Simultaneously close valve of VAG1318 pressure gauge
(lever perpendicular to direction of flow -arrow-).
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Fig. 38: Closing Valve Of VAG1318 Pressure Gauge (Lever Perpendicular To Direction Of Flow)
z Observe pressure drop on pressure gauge.
If pressure does not drop now:
z Check check-valve of Fuel Pump (FP).
If pressure drops again:
z Open valve of VAG1318 pressure gauge (lever in direction of flow).

z Switch ignition off after pressure has built up. Simultaneously clamp return line (with blue marking) fully
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closed (sealed).
If pressure does not drop now:
z Replace fuel pressure regulator
If pressure drops again:
z Check wire connections, O -rings at fuel distributor and fuel injectors for proper seal.
z Check pressure gauge for proper seal.
NOTE: Before disconnecting pressure gauge, release pressure by opening valve. Hold
a container in front of connection for this.
Fuel injectors, checking
z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31
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Checking internal resistance
z Disconnect connector at the injector to be tested.

z Connect multimeter at valve for resistance measurement.
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Fig. 40: Checking Fuel Injector Resistance

z Specified value: 12 - 13 ohm(at room temperature)
z Replace fuel injector. See FUEL INJECTORS, REMOVING AND INSTALLING .
Checking voltage supply
Test conditions
z Fuel Pump (FP) OK. Checking, see FUEL PUMP (FP) RELAY -J17-, CHECKING ACTIVATION .
z Fuse for fuel injectors OK.
See appropriate System Wiring Diagrams article.
z Disconnect connector at the injector to be tested.

z Connect VAG1527B voltage tester as follows:
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Fig. 41: Identifying Fuel Injector Harness Connector Terminals

FUEL INJECTOR CIRCUIT TEST - VOLTAGE SUPPLY

Harness connector terminal Measure to
1 Engine Ground
z Operate starter briefly (engine can also start).

z LED must light.
If LED does not light:
z Check wire connection between terminals 1 and fuse for injector valves for open circuit.
z Repair open circuit if necessary.
If LED lights, go to CHECKING ACTIVATION .
Checking activation
Test requirement
z Internal resistance of injector OK:

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z Slide back rubber grommet of fuel injector connector, but leave connector connected.
z Connect VAG1527B voltage tester between sockets 2 (signal) and 1 (B+).
Fig. 42: Connecting VAG1527B Voltage Tester Between Fuel Injector Sockets

z LED must blink.
NOTE: Voltage testers do not go out completely between activations by the ECM, but
rather continue to glow and then get slightly brighter during activation.
If LED does not blink:
z Connect VAG1598/31 test box at wiring harness to ECM, do not connect ECM. See WIRE AND
COMPONENT TEST USING VAG1598/31 TEST BOX .
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Fig. 43: Identifying Fuel Injector Harness Connector Terminals

z Check the following wire connections for open circuit and short circuit to Ground and B+:
FUEL INJECTOR CIRCUIT TEST - OPENS/SHORTS

Cylinder Fuel injector harness connector terminal VAG1598/31 test box socket
1 2 96
2 2 89
3 2 97
4 2 88
z Repair open circuit or short circuit if necessary.
If wire connection is OK:
z Replace Engine Control Module (ECM). See ENGINE CONTROL MODULE (ECM) (WITHOUT
Fuel distributor with fuel injectors, disassembling and assembling
1. - Fuel injector insert - 3 Nm

z Use locking fluid D 000 600 A2 when installing
2. - O-Ring
z Always replace
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3. - Fuel injectors -N30 through N33-

4. - Supply hose
5. - Return hose
6. - Fuel distributor
7. - Socket-head bolt - 10Nm
8. - Harness connector
z For injectors
z pieces

10. - O-Ring
z Always replace
11. - O-Ring
z Always replace
12. - Retaining clip

13. - O-Ring
z Always replace
14. - Retaining clip

z Check for proper seating at fuel injector and fuel distributor
15. - Intake manifold
Fig. 44: Exploded View Of Intake Manifold And Fuel Rail

Fuel injectors, removing and installing

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z Disconnect wiring/connectors at:

z Fuel injectors -N30-, -N31-, -N32-, -N33-
z Intake Air Temperature (IAT) sensor - G42-
z Camshaft Position (CMP) sensor 2 -G163 -
z Throttle valve control module -J338-
z Charge air pressure sensor -G31-
z Detach cable channel to fuel injectors.

z Remove 2 socket -head bolts for fuel distributor.
z Disconnect fuel supply and return lines at quick - release connection in front of right suspension strut.
z Disconnect vacuum hose from fuel pressure regulator.
z Place fuel distributor toward front.
WARNING: The fuel system is under pressure. When opening the system, place a rag
around connections then release pressure by carefully prying open
connection.
z Disengage retaining clip and remove fuel injector.
NOTE: Fuel lines must be disconnected before replacing fuel distributor.
Installation is in reverse order of removal, noting the following:
z O-rings at all opened connections. (Never remove plastic cap from valve head or replace front O -ring,
pry O-ring off over plastic cap).
z Lightly lubricate O-rings with clean engine oil.
z Make sure fuel injectors are in place and seated correctly.
z Check clip for unobstructed fitting.
z Place fuel distributor, with fuel injectors securely installed, on intake manifold and press in evenly.
Tightening torque
Fuel distributor at intake manifold: 10 Nm.
Injection quantity, proper seal and spray pattern of fuel injectors, checking
z VAG1348/3-2
z VAG1348/3A
z VAG1594A
z VAG1602
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or
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Test requirement
z Fuel pressure OK, checking. See SYSTEM PRESSURE, FUEL PRESSURE REGULATOR AND
RESIDUAL PRESSURE, CHECKING .
Test sequence
z Remove fuel distributor including fuel injectors from intake manifold. See FUEL INJECTORS,
REMOVING AND INSTALLING . Fuel lines remain connected.
z Bridge terminals 1 and 65 at test box using adapter cables from VAG1594A connector test kit (this step
supplies Ground to one side of relay coil of Fuel Pump -FP- relay).
Checking for proper seal
z Turn ignition on.
NOTE: After switching ignition on, Fuel Pump (FP) will run continuously, even with
engine not running. This is true because: Fuel Pump (FP) relay is supplied with
B+ via central electrics after ignition is switched on. Fuel Pump (FP) relay
Ground connection is via the cable bridge in test box.
z Check to make sure fuel injectors are not leaking (visual check). With Fuel Pump (FP) running, only 1 - 2
drops per minute may drip out per injector.
z If fuel loss is greater, stop Fuel Pump (FP) from running (End Output DTM) and replace malfunctioning
fuel injector. See FUEL INJECTORS, REMOVING AND INSTALLING .
Checking injection quantity
z Insert fuel injector to be tested in a measuring glass from VAG1602 injection quantity test device.
z Connect one terminal of fuel injector to engine Ground using an adapter cable and an alligator clip from
VAG1594A connector test kit.
z Connect the second terminal of fuel injector to B+ using VAG1348/3A remote control, VAG1348/3 -2
adapter cable and assisting cable.
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Fig. 46: Connecting VAG1348/3A Remote Control To Fuel Injector

z Switch ignition on.

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z Fuel Pump (FP) must run

z Activate VAG1348/3A remote control for 30 seconds.
z Perform measurement on all fuel injectors.
z After all four fuel injectors have been activated, place measuring glasses on an even surface.
z Specified value for each fuel injector: 145 = 12 ml
z If measured value of one or more fuel injectors is outside of specified range, switch Fuel Pump (FP) off
(switch ignition off) and replace malfunctioning fuel injector. See FUEL INJECTORS, REMOVING
AND INSTALLING .
NOTE: Also check spray pattern when checking injection quantity. Spray pattern must
be the same for all injectors.
z Remove fuel injectors together with fuel distributor. See FUEL INJECTORS, REMOVING AND
INSTALLING .
Fuel Pump (FP) relay -J17-, checking activation
z VAG1526A
z VAG1594A
z VAG1598/31
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Test requirement
Voltage is supplied to the Fuel Pump (FP) and several components of the injection system via the Fuel Pump
(FP) relay -J17-.
For Fuel Pump (FP) relay -J17- to close, it is required that engine is turning. This means that the relay does not
receive Ground (via ECM) until the ECM recognizes RPM signals.
NOTE: Fuel Pump (FP) relay is located at position 4 of micro-central electrics in

driver's footwell, left.
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Fig. 48: Locating Fuel Pump (FP) Relay (Position 4)

z Battery voltage at least 11 V
Function test of Fuel Pump (FP) relay
z Remove driver-side storage compartment.
See DRIVER'S STORAGE COMPARTMENT, REMOVING .
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z Initiate Output Diagnostic Test Mode (see OUTPUT DIAGNOSTIC TEST MODE (DTM) ) and
activate Evaporative Emission (EVAP) canister purge regulator valve -N80-.
z Fuel Pump (FP) relay (at position 4 of micro -central electrics in driver's footwell, left) must trigger
and Fuel Pump (FP) must run.

If relay does not trigger:
z Check activation of Fuel Pump (FP) relay.
If Fuel Pump (FP) does not run:
z Check voltage supply for fuel pump (FP) and components (via Fuel Pump -FP- relay). See CHECK
VOLTAGE SUPPLY FOR FUEL PUMP (FP) AND COMPONENTS .
Check activation of Fuel Pump (FP) relay
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z Connect socket 65 and socket 2 of test box to each other using wire from VAG1594 connector test kit.
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z Fuel Pump (FP) relay (at position 4 of micro -central electrics in driver's footwell, left) must
trigger.
If relay triggers now, but didn't during output DTM:
If relay does not trigger:

z Remove Fuel Pump (FP) relay.
z Connect multimeter to terminal 19 of relay socket and Ground for voltage measurement.
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Fig. 51: Identifying Fuel Pump Relay Sockets In Relay Carrier


z Specification: approx. battery voltage
z Check wire connections.
See appropriate System Wiring Diagrams .

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Fig. 52: Identifying Fuel Pump Relay Sockets In Relay Carrier

z Check the following wire connection for open circuit and short circuit to Ground and B+:
FUEL PUMP RELAYCIRCUIT TEST - OPENS/SHORTS

Micro-central electronics in drivers - side footwell, left, position 4 VAG1598/31 test box
terminal socket
16 65

z If wire connections are OK, replace Fuel Pump (FP) relay -J17-.
Check voltage supply for Fuel Pump (FP) and components
z Remove fuse Nos. S28, S32, S34 and S43 from fuse holder.
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Fig. 53: Identifying Fuse Holder

z Initiate Output Diagnostic Test Mode (see OUTPUT DIAGNOSTIC TEST MODE (DTM) ) and
activate Evaporative Emission (EVAP) canister purge regulator valve -N80-.
z Connect multimeter to Ground and to one terminal of the following fuses in fuse holder for voltage
measurement.
FUSES FOR VOLTAGE SUPPLY TO FUEL PUMP

Locking clip Specified value at one of the terminals
S28 approx. battery voltage
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If specified values are not obtained:
z Repeat test at another terminal of fuse socket.
If specified values are not obtained again:
z Check wire connections.
z If wire connections are OK, replace Fuel Pump (FP) relay -J17-.
Mass Air Flow (MAF) sensor - G70-, checking
z VAG1526A
z VAG1594A
z VAG1598/31
{ or
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Test conditions
z Coolant Temperature less than 80 °C

z Electrical consumers switched off (radiator fan must NOT run during test)
z A/C switched off
z Fuse for Mass Air Flow (MAF) sensor OK
Checking function
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Engine must run at idle for this.
Fig. 55: VAG 1551 Scan Tool Display - MAF Sensor, Checking (1 Of 4)
NOTE: During Basic Setting, the Evaporative Emission (EVAP) canister purge regulator
valve (EVAP valve -N80-) is closed and the A/C compressor is switched off
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z Check specified values for load detection.
DISPLAY GROUP 2: AIR MASS TAKEN IN WITH ENGINE AT IDLE AND OPERATING
TEMPERATURE
Display fields
1 2 3 4
Display group 2: Air mass taken in with engine at idle and operating temperature
Display xxx /min xx.x x.x ms xxx.x g/s
%
Indicated Engine Load mean injection time Air mass
speed
(RPM)
(in
increments
of 40)
Work min.: 800 min.: min.: 2.0 ms min.: 2.0 g/s
area RPM 15 % max.: 19.0 ms max.: 170.0 g/s
max.: 6800 max.:
RPM 175 %
Specified 800 - 920 15.0 - 2.0 - 4.0 ms 2.0 - 4.5 g/s
value: RPM 25.0
%
Note: --- --- If specified value is not obtained: If specified value is not obtained:
Evaluation display field 3, see Evaluation display field 4, see
DISPLAY FIELDS DISPLAY FIELDS
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SPECIFICATION SPECIFICATION
z Press -->button.
Evaluation display group 002
EVALUATION DISPLAY GROUP 002 (1 OF 2)

Display
field: 3 Possible cause Corrective action
less than z Smaller values can only occur
2.0 ms when driving in deceleration
mode
larger than z Engine under load due to z Reduce load (A/C system/power
4.0 ms power accessories steering/generator)
z Poor idle (does not run on all z Check spark plugs
cylinders) z Check fuel injectors, see FUEL INJECTORS,
CHECKING
z Throttle valve control module z Check throttle valve control module. See
-J338- malfunctioning THROTTLE VALVE CONTROL MODULE
-J338-, CHECKING .
EVALUATION DISPLAY GROUP 002 (2 OF 2)

Display
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Smaller z Large un-metered air mass zCheck intake system for leaks (unmetered air).
than 2.0 between intake manifold and See INTAKE AIR SYSTEM, CHECKING
g/s Mass Air Flow (MAF) sensor FOR LEAKS (UN-METERED AIR)
z Voltage supply of Mass Air z Check voltage supply and wire connections. See
Flow (MAF) sensor and wire CHECK VOLTAGE SUPPLY FOR MASS
connections to engine AIR FLOW (MAF) SENSOR .
Larger z Engine under load due to z Reduce load (A/C system/power
than 4.5 power accessories. steering/generator)
g/s
z Voltage supply of Mass Air z Check voltage supply and wire connections. See
Flow (MAF) sensor and wire CHECK VOLTAGE SUPPLY FOR MASS
connections to engine AIR FLOW (MAF) SENSOR .
Check voltage supply for Mass Air Flow (MAF) sensor
z Disconnect connector at Mass Air Flow (MAF) sensor.

z Connect multimeter for voltage measurement as follows.
Fig. 59: Identifying Mass Air Flow Sensor Harness Connector Terminals
MAF SENSOR CIRCUIT TEST - VOLTAGE SUPPLY

2 Engine Ground
z Operate starter briefly.

NOTE: Voltage is supplied to Mass Air Flow (MAF) sensor via Fuel Pump (FP) relay.
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z Check wire connection from terminal 2 of connector to Fuel Pump (FP) relay via fuse for open circuit and
short circuit to Ground:
z Connect multimeter to terminal 2 and terminal 3 of connector for voltage measurement.

NOTE: Ground from the ECM is present at terminal 3 of connector.
z Check wire connections. See CHECK WIRE CONNECTIONS FOR MASS AIR FLOW (MF)
SENSOR .
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z Connect multimeter to terminal 3 and terminal 4 of connector for voltage measurement.

z Specification: approx. 5 V
z Check wire connections. See CHECK WIRE CONNECTIONS FOR MASS AIR FLOW (MF)
SENSOR .
Check wire connections for Mass Air Flow (MF) sensor
NOTE: Signal wire is also checked during wire test.
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MAF SENSOR CIRCUIT TEST - OPENS/SHORTS

Harness connector terminal VAG1598/31 test box socket
3 27
4 53
5 29

z Also check all wires for short circuit to each other.
z Replace Mass Air Flow (MAF) sensor -G70-.
Intake air system, checking for leaks (un-metered air)
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Fig. 63: Identifying Special Tool VAS5051

or

z Engine leak detection spray G 001 800 A1
NOTE: z Leak detection spray is drawn into intake system along with un-metered
air by vacuum in intake system. Leak detection spray decreases ignition
quality and performance of the fuel mixture. This causes a reduction in
engine speed and a sharp increase of CO content.
z Always observe the safety precautions printed on can.
Test sequence
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Fig. 64: VAG 1551 Scan Tool Display - Intake Air System, Checking For Leaks (1 Of 4)
z Press buttons -0- and -8- to select "Read Measuring Value Block" and press -Q- button to confirm input.
Indicated on display: (1 - 4 = display fields)
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z Note engine speed in display field 1.

z Systematically spray parts of intake system with engine leak detection spray.
If engine speed does not change:
z Press -->button.
If engine speed decreases:
z Press -->button.
z Press buttons -0- and -6- to select "End output" and press -Q- button to confirm input.
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z Check sprayed portions of intake system for leaks and repair malfunction.
OXYGEN SENSOR CONTROL, CHECKING
Function of oxygen sensor control before catalytic converter
NOTE: z Oxygen sensor compares oxygen content of air with residual oxygen
content in exhaust and delivers a voltage signal to the control module.
z The voltage signal "mixture rich (too little residual oxygen)" is 0.7 - 1.1 V
(relative to reference Ground).
z The voltage signal "mixture lean (too much residual oxygen)" is -0.1 to
+0.3 V (relative to reference Ground).
z During transition from "rich" to "lean" and vice versa ("lambda" = 1.0) the
voltage jumps from range of 0.7 to 1.1 V to range of -0.1 to +0.3 V or vice
versa.
z Due to the steep voltage jump, oxygen sensor control cannot maintain the
ideal mixture of "lambda" = 1.0 as constant. Oxygen sensor control
constantly fluctuates back and forth between the conditions "slightly too
lean" and "slightly too rich."
NOTE: If voltage change does not occur or occurs only slowly, the following
malfunctions could be present:
z Slits or holes in sensor head clogged.

z Sensors suffered thermal overload.
z Transition resistance in signal wire or Ground wire.
z Sensor too cold, sensor heating not functioning.
z Sensor damaged by contact spray or similar substance (contact spray is
drawn through the fine hollow interiors by thermal fluctuations and
capillary action into the electrical wiring in sensor).
z Sensor damaged by silicon fumes (The use of sealing materials containing
silicon leads to traces of silicon to be drawn in by the engine. These traces
are not combusted and damage the oxygen sensors).
Oxygen sensor and oxygen sensor control before catalytic converter, checking
z VAG1526A
z VAG1594A
z VAG1598/31
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{ or
Fig. 68: Identifying Special Tools And Shop Equipment

Test conditions
z For the defined troubleshooting procedure, it is possible, to switch oxygen sensor control off by selecting
display group 99 under "Basic Setting" and switch it on again under "Read Measuring Value Block."
z After selecting display group 99 (either in "Basic Setting" or "Read Measuring Value Block"), it is
possible to switch back and forth between "Basic Setting" (function 04) and "Read Measuring Value
Block" (function 08) by pressing buttons 4 or 8 on the VAG1551.
z Once function 04 "Basic Setting" is exited, oxygen sensor control is automatically switched on again.
z The 4-pin harness connectors for the oxygen sensor before catalytic converter (black) and for the oxygen
sensor behind catalytic converter (brown) are located under a cover -2- at vehicle floor.
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Fig. 69: Locating Oxygen Sensors And Cover

z Road test performed and DTC memory erased

Function test
Fig. 70: VAG 1551 Scan Tool Display - HO2S And HO2S Control Before Catalytic Converter, Function
Test (1 Of 3)
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Test (2 Of 3)
Test (3 Of 3)
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z Check oxygen sensor status in display field 1.
NOTE: "Oxygen sensor status" indicates status of oxygen sensor control and oxygen
sensor.
DISPLAY GROUP 30: OXYGEN SENSOR STATUS

Display fields
1 2 3 4
Display group 30: Oxygen sensor status
Display XXX XXX
Indicated Oxygen sensor status, bank 1, sensor 1 Oxygen sensor status, bank 2, sensor 1
Work area 0 = off 0 = off
1 = on 1 = on
Specified 111 110
value:
Note: If specified value is not obtained, see CHECKING PRIMARY VOLTAGE
If specified value is obtained but there is a malfunction stored in DTC memory, see
CHECKING OXYGEN SENSOR ADAPTATION VALUES AND CONTROL
Significance of 3 digit indication of display group 030
SIGNIFICANCE OF 3 DIGIT INDICATION OF DISPLAY GROUP 030

X X X Display field 1
1 Oxygen sensor control active
1 Operational readiness of oxygen sensor
1 Condition of oxygen sensor heating
NOTE: The first field of the 3 digit indication (heating) fluctuates between 0 and 1.
Checking oxygen sensor adaptation values and control
z Press -C- button.

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Fig. 73: VAG 1551 Scan Tool Display - Checking HO2S Adaption Values And Control (1 Of 2)
z Check oxygen sensor control in display fields 1 and 2.
DISPLAY GROUP 32: OXYGEN SENSOR ADAPTATION VALUES

Display fields
1 2 3 4
Display group 32: Oxygen sensor adaptation values
Display xx.x % xx.x %
Indicated Oxygen sensor adaptation value Oxygen sensor adaptation value bank 1,
bank 1, sensor 1 at idle (additive) sensor 1 at partial throttle (multiple)
Work area -25.0 to 25.0 % -25.0 to 25.0 %
Specified -10.0 to 10.0 % -10.0 to 10.0 %
value: can fluctuate slightly can fluctuate slightly
Note: If specified value is not obtained, see CHECKING PRIMARY VOLTAGE .
z Press -C- button.

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Fig. 74: VAG 1551 Scan Tool Display - Checking HO2S Adaption Values And Control (2 Of 2)
z Check oxygen sensor control in display fields 1 and 2.
DISPLAY GROUP 33: OXYGEN SENSOR CONTROL

Display fields
1 2 3 4
Display group 33: Oxygen sensor control
Display xx.x % x.xxx V
Indicated Oxygen sensor control Bank Oxygen sensor voltage bank 1
1
Work area -25.0 to 25.0 % 0.000 - 1.000 V
Specified Value must fluctuate at least Value must fluctuate approx. 0.3 V in the range
value: 2 % in the range -10.0 to 0.000 - 1.000 volts
10.0 %
Note: If specified value is not If specified value is not obtained, see Evaluation
obtained, continue with test. display group 033. See DISPLAY FIELDS
SPECIFICATION
If specified value in display field 1 is not obtained or if value does not fluctuate at least 2 %:
z Road test vehicle in order to free oxygen sensor of possible residue and repeat test.
If specified value in display field 1 is not obtained even after road test or if value does not fluctuate at least 2 %:
z See CHECKING PRIMARY VOLTAGE .

z Check oxygen sensor heating. See OXYGEN SENSOR HEATING FOR OXYGEN SENSORS
BEFORE AND AFTER CATALYTIC CONVERTER, CHECKING .
z Check oxygen sensor before catalytic converter for aging. See OXYGEN SENSOR AGING, OXYGEN
SENSOR BEFORE CATALYTIC CONVERTER, CHECKING .
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EVALUATION OF DISPLAY GROUP 32 (1 OF 2)

Display field: 1 / 2 Possible cause Corrective action
Oxygen sensor z Leak in intake area (pressure z Check intake system for leaks
adaptation values in side between turbocharger and and repair un-metered air, see
range: -10.0 to - 25.0 % intake manifold) INTAKE AIR SYSTEM,
CHECKING FOR LEAKS
(UN-METERED AIR)
z Oil thinning z Change oil or perform swift
road test on a deserted road
z High oil consumption
z Mass Air Flow (MAF) sensor z Check Mass Air Flow (MAF)
malfunctioning sensor, see MASS AIR FLOW
(MAF) SENSOR - G70-,
CHECKING
z Evaporative Emission (EVAP) z Check Evaporative Emission
canister purge regulator valve (EVAP) Canister Purge
remains stuck in open position Regulator Valve, see TANK
VENTILATION,
CHECKING
z Fuel pressure too high z Check fuel pressure
regulator, see SYSTEM
PRESSURE, FUEL
PRESSURE REGULATOR
AND RESIDUAL
PRESSURE, CHECKING
z Fuel injector does z Check fuel injectors, see FUEL
not close INJECTORS, CHECKING
z Oxygen sensor z Check oxygen sensor heating,
heating see OXYGEN SENSOR
malfunctioning HEATING FOR OXYGEN
z Oxygen sensor SENSORS BEFORE AND
malfunctioning AFTER CATALYTIC
CONVERTER, CHECKING
EVALUATION OF DISPLAY GROUP 32 (2 OF 2)

Display field:
1/2 Possible cause Corrective action
Oxygen sensor z Un-metered air in intake z Check intake system for leaks and repair un-
values in area metered air, see INTAKE AIR SYSTEM,
range: 10.0 - CHECKING FOR LEAKS (UN-METERED
25.0 % AIR)
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z Fuel pressure too low Check fuel pressure regulator, see SYSTEM
z
PRESSURE, FUEL PRESSURE
REGULATOR AND RESIDUAL PRESSURE,
CHECKING
z Mass Air Flow (MAF) z Check Mass Air Flow (MAF) sensor, see MASS
sensor malfunctioning AIR FLOW (MAF) SENSOR - G70-,
CHECKING
z Oxygen sensor heating z Check oxygen sensor heating, see OXYGEN
malfunctioning SENSOR HEATING FOR OXYGEN
z Oxygen sensor
SENSORS BEFORE AND AFTER
malfunctioning CATALYTIC CONVERTER, CHECKING
z Fuel injector does not z Check fuel injectors, see FUEL INJECTORS,
open or opens only CHECKING
partially
z Evaporative Emission z Check Evaporative Emission (EVAP) Canister
(EVAP) Canister Purge Purge Regulator Valve, see EVAPORATIVE
Regulator Valve sticks EMISSION (EVAP) CANISTER PURGE
REGULATOR VALVE -N80-, CHECKING
EVALUATION OF DISPLAY GROUP 33

Display
Constant z Open circuit in wire 4 between z See CHECKING PRIMARY VOLTAGE
approx. oxygen sensor and control
0.450 V module
z Open circuit in wire 3 between
oxygen sensor and control
module
Constant z Oxygen sensor malfunctioning z Replace oxygen sensor
approx.
0.200 V
Larger than z Short circuit to B+ in wire 4 z Check oxygen sensor wiring and oxygen
1.100 V between oxygen sensor and sensor before catalytic converter, see
control module CHECKING OXYGEN SENSOR
Smaller than WIRING
z Short circuit to Ground in wire
0.150 V 4 between oxygen sensor and
control module
Checking primary voltage
z Disconnect 4-pin harness connector (black) to oxygen sensor before catalytic converter.
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Fig. 75: Disconnecting 4-Pin Harness Connector To Oxygen Sensor

z Connect multimeter between terminals 3 and 4 for voltage measurement.
Fig. 76: Identifying Oxygen Sensor Harness Connector Terminals

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z Specification: 0.400 - 0.500 V
z Check oxygen sensor wiring.
z Replace oxygen sensor before catalytic converter -G39-.
Checking oxygen sensor wiring
z Disconnect 4-pin harness connector (black) to oxygen sensor before catalytic converter.

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z Check the following wire connections for open circuit.
OXYGEN SENSOR CIRCUIT TEST - OPENS

3 51
4 7

z Check wires for short circuit to each other.
z Replace Engine Control Module (ECM), see ENGINE CONTROL MODULE (ECM) (WITHOUT
Oxygen sensor aging, oxygen sensor before catalytic converter, checking
z VAG1788/10 RPM adjuster
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Fig. 79: Identifying Special Tools - VAG1788/10 RPM Adjuster

or
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Fig. 80: Identifying Special Tools - VAS5051

Test requirement
z Coolant temperature at least 80 °C (Display group 4, display field 3)
Test sequence
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Fig. 81: VAG 1551 Scan Tool Display - HO2S Aging, HO2S Before Catalytic Converter, Checking (1 Of
3)
3)
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3)
z Adjust engine speed using VAG1788/10 to 1800 - 2200 RPM.

z Continue test as soon as display 4 indicates "Test ON."
NOTE: This process can take a few minutes.
DISPLAY GROUP 34: DIAGNOSTIC OXYGEN SENSOR AGING

Display fields
1 2 3 4
Display group 34: Diagnostic oxygen sensor aging
Display xxxx RPM xxx °C x.x s ---
Indicated Engine speed Exhaust Period duration Oxygen sensor Diagnostic
(RPM) temperature before catalytic converter condition
Work area 0 - 6800 70 - 850 °C 0 - 3.0 s Test OFF
Test ON
B1-S2 OK
B1-S2 not OK
Specified 1800 - 2200 more than 350 ° 0.0 - 2.7 s B1-S2 OK
value: RPM C
Note: If specified value is not obtained, see
CONTINUATION
Note for display field 2:
Calculated value from engine speed and engine load.
Note for display field 3 and 4:
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Period duration is the time between two oxygen sensor voltage jumps (e.g. rich - lean - rich) and is therefore a
measurement of the aging condition of the oxygen sensor. If the specified time is exceeded, display field 4 will
indicate = B1-S1 not OK.
Continuation
If specified value in display field 3 and 4 is not obtained:
If specified value in display field 3 and 4 is not obtained, even after road test:
Oxygen sensor and oxygen sensor control behind catalytic converter, checking
NOTE: z Oxygen sensor control behind the catalytic converter is responsible for
final control correction. It is the primary sensor and can override the
signal from the oxygen sensor control before the catalytic converter.
Fig. 84: Oxygen Sensor Control Graph

z It corrects slight changes in the mixture (i.e. enrichment) via the oxygen
sensor before catalytic converter by holding the oxygen sensor control
before catalytic converter at its higher or lower limit for a specific time
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(duration). If this time is in the positive range (i.e. 50 ms), mixture is shifted
in the -enrich- direction. If this time is in the negative range (i.e. -50 ms),
mixture is shifted in the -lean- direction.
The 4-pin harness connector (brown) for the oxygen sensor behind catalytic and oxygen sensor heating is
located under a cover at vehicle floor.
Fig. 85: Locating HO2S 4-Pin Harness Connectors

z VAG1526A
z VAG1594A
z VAG1598/31
z VAG1788/10 RPM adjuster
or
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Test conditions
z Road test performed and DTC memory erased.

Test sequence
Fig. 87: VAG 1551 Scan Tool Display - HO2S And HO2S Control Behind Catalytic Converter, Checking
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(1 Of 5)
(2 Of 5)
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(3 Of 5)

z Continue test as soon as display field 2 indicates an exhaust temperature of more than 350 °C.
NOTE: This process can take a few minutes.
z Press -C- button.

(4 Of 5)
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2000 Audi TT
(5 Of 5)
z Check oxygen sensor status for oxygen sensor behind catalytic converter in display field 2.
NOTE: "Oxygen sensor status" indicates status of oxygen sensor control and oxygen
sensor.
DISPLAY GROUP 30: OXYGEN SENSOR STATUS WITH ENGINE AT IDLE

Display fields
1 2 3 4
Display group 30: Oxygen sensor status with engine at idle
Display XXX XXX
Indicated Oxygen sensor status, bank 1, sensor 1 Oxygen sensor status bank 2, sensor 1
Work area 0 = off 0 = off1 = on
1 = on
Specified 111 110
value:
Note: If specified value is not obtained, see OXYGEN SENSOR HEATING FOR OXYGEN
SENSORS BEFORE AND AFTER CATALYTIC CONVERTER, CHECKING
Significance of 3 digit indication of display group 030
SIGNIFICANCE OF 3 DIGIT INDICATION OF DISPLAY GROUP 030

X X X Display field 2
1 Oxygen sensor control active
1 Operational readiness of oxygen sensor
1 Condition of oxygen sensor heating
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NOTE: z Oxygen sensor control of oxygen sensor behind catalytic converter (B1 -
S2) is not active without engine load.
z The first position of the 3 digit indication (heating) fluctuates between 0
and 1.
Checking oxygen sensor control behind catalytic converter
z Press -C- button.
Fig. 92: VAG 1551 Scan Tool Display - Checking Oxygen Sensor Control Behind Catalytic Converter (1
Of 2)
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Fig. 93: VAG 1551 Scan Tool Display - Checking Oxygen Sensor Control Behind Catalytic Converter (2
Of 2)
z Check oxygen sensor voltage in display field 2.

z Check duration of oxygen sensor control before catalytic converter in display field 3 and diagnostic result
in display field 4.
DISPLAY GROUP 37: DIAGNOSTIC OXYGEN SENSOR CONTROL SYSTEM

Display fields
1 2 3 4
Display group 37: Diagnostic oxygen sensor control system
Display xxx % x.xxx volts xxx ms ---
Indicated Engine Oxygen sensor voltage Duration of oxygen Diagnostic condition
load bank 2, sensor 1 sensor control before
catalytic converter,
bank 1
Work 15 - 0.000 - 1.000 V -1200 to 1200 ms Test OFF
area 150 % Test ON
System OK
System not OK
Specified 12 - 30 0.100 - 0.900 V -150 to 150 ms SYST. i.O.
value: %
Note: If specified value is not If value climbs to above If "System not OK" is
obtained: Evaluation display 300 ms, this indicates a displayed: Check DTC
field 2, see DISPLAY leaking exhaust system memory. See DIAGNOSTIC
FIELDS or malfunctioning TROUBLE CODE (DTC)
SPECIFICATION oxygen sensor MEMORY, CHECKING
AND ERASING .
Note for display field 3:
Oxygen sensor control behind catalytic converter is superior to oxygen sensor control before catalytic
converter and is the primary control. It corrects slight changes in the mixture (i.e. enrichment or thinning) by
holding the oxygen sensor control before catalytic converter at its higher or lower point for a specific time
(duration). If this time is in the positive range (i.e. 50 ms), mixture is shifted in the -enrich- direction. If this
time is in the negative range (i.e. 50 ms), mixture is shifted in the -lean- direction.
EVALUATION OF DISPLAY GROUP 37

Display
Constant z Open circuit in wire 4 z See CHECKING PRIMARY VOLTAGE
approx. 0.450 between oxygen sensor and
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V control module
z Open circuit in wire 3
between oxygen sensor and
control module
Larger than z Short circuit to B+ in wire 4 z Check oxygen sensor wiring and oxygen sensor
1.100 V between oxygen sensor and behind catalytic converter, see CHECKING
control module OXYGEN SENSOR WIRING
Smaller than z Short circuit to Ground in
0.150 V wire 4 between
oxygen sensor and control

module
Continuation
If specified value in display field 3 and 4 is not obtained:
If specified value in display field 3 and 4 is not obtained, even after road test:
NOTE: If oxygen sensor voltage is OK and duration of oxygen sensor behind catalytic
converter is still above 1200 ms even after a road test, this indicates an aged
oxygen sensor before catalytic converter.
Checking primary voltage
z Disconnect 4-pin harness connector (brown) to oxygen sensor behind catalytic converter.
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z Connect multimeter between terminals 3 and 4 for voltage measurement.
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z Specification: 0.400 - 0.500 V
z Check oxygen sensor wiring.
z Replace oxygen sensor behind catalytic converter
Checking oxygen sensor wiring
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z Check the following wire connections for open circuit.
HO2S BEHIND TWC CIRCUIT TEST - OPENS

3 68
4 69

z Check wires for short circuit to each other.
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Oxygen sensor heating for oxygen sensors before and after catalytic converter, checking
z VAG1526A
z VAG1594A
z VAG1598/31

Test conditions

z Fuse for oxygen sensor heating OK
Test sequence
z Disconnect 4-pin harness connector (black) to oxygen sensor before catalytic converter, or...
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Fig. 100: Identifying Oxygen Sensor Terminals

z Connect multimeter between terminals 1 and 2 of relevant connector for resistance measurement.
z Specified value at room temperature: 1 - 5 ohm
NOTE: At higher temperatures, resistance climbs sharply.
z Replace oxygen sensor.
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If specified value is met:
z See CHECKING VOLTAGE SUPPLY OF OXYGEN SENSOR HEATING .
Checking voltage supply of oxygen sensor heating
z Connect multimeter between terminals 1 (B+) and 2 (Ground) for voltage measurement.

z Start engine.
z Specification: approx. battery voltage, possibly fluctuating
NOTE: z At certain operating points, the ECM "pulses" the Ground for oxygen
sensor heating. This means that the Ground is switched on and off at
these points. It is therefore possible that the voltage displayed on the
tester will fluctuate.
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z The ECM switching oxygen sensor heating on and off can be observed, if
necessary, in the function "Read Measuring Value Block" display group
number 041.
If there is no voltage:
z Connect multimeter for voltage measurement as follows:
HO2S HEATING CIRCUIT TEST - VOLTAGE SUPPLY (TERMINAL 1)

1 (B+) Vehicle Ground

If there is no voltage again:
z Check wire connection from terminal 1 of connector to Fuel Pump (FP) relay via fuse for open circuit:
If voltage supply is OK:

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HO2S HEATING CIRCUIT TEST - VOLTAGE SUPPLY (TERMINAL 2)

2 (Ground activation of Engine Control Module -ECM -) B+
z Start engine.
z Specification: approx. battery voltage, possibly fluctuating
If there is no voltage:

z Check the following wire connection for open circuit:
Oxygen sensor heating for oxygen sensor before catalytic converter (black connector)
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HO2S BEFORE TWC HEATING CIRCUIT TEST - OPENS

2 5
Oxygen sensor heating for oxygen sensor behind catalytic converter (brown connector)
HHO2S BEHIND TWC HEATING CIRCUIT TEST - OPENS

2 63
If wire connection is OK, but there is no Ground supply for oxygen sensor heating:
Oxygen sensor, removing and installing
z 3337/9 socket wrench insert SW16

z Locking fluid G 052 112 A3

Procedure
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z Disconnect 4-pin harness connector of relevant oxygen sensor and lay it to side.
Fig. 105: Disconnecting 4-Pin Harness Connector Of Relevant Oxygen Sensor

NOTE: z Identification of oxygen sensor before catalytic converter: black

connector.
z Identification of oxygen sensor behind catalytic converter: brown
connector.
z Unscrew oxygen sensor using special tool 3337/9.
Note the following when installing:
NOTE: z Oxygen sensor wiring must always be secured in the same position when
installing so that contact with the exhaust pipe is avoided.
z Oxygen sensor threads are coated with an assembly paste. This paste
must not contact sensor openings.
z Tightening torque: 55 Nm
SECONDARY AIR INJECTION (AIR) VALVE, CHECKING
The secondary air system results in quicker heating and therefore earlier operating readiness of the catalytic
converter following cold start.
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Principle
Due to over-enrichment of the mixture during the cold start phase, there is an increased amount of un-
combusted carbon monoxide in the exhaust. Secondary Air Injection (AIR) improves secondary oxidation in the
catalytic converter and therefore reduces emissions. The heat produced by secondary oxidation greatly reduces
start -up time for the catalytic converter, therefore improving exhaust quality during the cold start phase
significantly.
Function
z In the cold start phase, the ECM - 2 - activates the secondary air pump - 12 - via the relay for secondary
air pump -1-. Air reaches the combination valve for Secondary Air Injection (AIR) - 10 -.
z Parallel to this, the Secondary Air Injection (AIR) solenoid valve - 3 - is activated, which permits
negative pressure to reach the combination valve for Secondary Air Injection (AIR) - 10 - and the
pressure unit for boost pressure regulation - 7 -. The combination valve for Secondary Air Injection (AIR)
thereby opens the path for secondary air to the exhaust channels of the cylinder head.
z To prevent unnecessary torque loss, secondary air is led around the turbocharger -8-. For this, the boost
pressure regulation pressure unit opens the boost pressure valve. The pressure unit, designed as a double
reservoir, has a vacuum connection for this on the low pressure side.
1. - Secondary Air Injection (AIR) pump relay -J299-

2. - Motronic Engine Control Module (ECM) -J220-
5. - Check-valve
z Installed position (light/dark half): Arrow points in direction of flow, as shown in figure
6. - Vacuum reservoir
7. - Pressure unit for boost pressure regulation
8. - Turbocharger
9. - Cylinder head
10. - Combination valve for Secondary Air Injection (AIR)
11. - Air filter
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Fig. 106: Identifying Secondary Air Injection (AIR) System Components

Secondary Air Injection (AIR) solenoid valve -N112-, checking
z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31
z VAS5051 tester
or
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Component location, see COMPONENT LOCATIONS, OVERVIEW .
Test requirement
z Perform Output Diagnostic Test Mode
z Unbolt bracket for Secondary Air Injection (AIR) solenoid valve from intake manifold.
z Disconnect harness connector from Secondary Air Injection (AIR) valve -N112-.
Fig. 108: Checking Secondary Air Injection (AIR) Solenoid Valve Internal Resistance

z Specified value: 25 - 35 ohm
z If specified value is not obtained, replace Secondary Air Injection (AIR) solenoid valve -N112-.
z Disconnect harness connector from Secondary Air Injection (AIR) valve -N112-.
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Fig. 109: Identifying Secondary Air Injection (AIR) Solenoid Valve Harness Connector Terminals
SECONDARY AIR INJECTION (AIR) SOLENOID VALVE CIRCUIT TEST - VOLTAGE

SUPPLY
1 Engine Ground
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z LED must light
z Perform the following tests (marked with diamonds):

z Fuse for Secondary Air Injection (AIR) solenoid valve
Fig. 110: Fuse Holder

z Check wire connection from terminal 1 of connector to Fuel Pump (FP) relay via fuse for open
circuit:
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z Check Fuel Pump (FP) relay. See FUEL PUMP (FP) RELAY -J17-, CHECKING ACTIVATION .
Checking activation
SECONDARY AIR INJECTION (AIR) SOLENOID VALVE CIRCUIT TEST - ACTIVATION

2 B+
z Initiate Output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) solenoid valve -
N112-. See OUTPUT DIAGNOSTIC TEST MODE (DTM) .
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Fig. 113: VAG 1551 Scan Tool Display - Secondary Air Injection (AIR) Solenoid Valve
z LED must blink.
If LED does not blink or if it remains constantly lit:
SECONDARY AIR INJECTION (AIR) SOLENOID VALVE CIRCUIT TEST - OPENS/SHORTS
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2 9
Secondary Air Injection (AIR) pump relay -J299 -, checking and activating
z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31

Checking and activating
Component location, see COMPONENT LOCATIONS, OVERVIEW .
z Initiate output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) pump relay -
J299-. See OUTPUT DIAGNOSTIC TEST MODE (DTM) .
z Secondary Air Injection (AIR) pump relay -arrow- (under cover, left at bulkhead) must trigger and
the Secondary Air Injection (AIR) pump motor -V101- must run.
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Fig. 116: Identifying Secondary Air Injection (AIR) Pump Relay Location
A. - If relay does not trigger:

{ Check voltage supply of Secondary Air Injection (AIR) pump. See CHECKING VOLTAGE
SUPPLY OF SECONDARY AIR INJECTION (AIR) PUMP RELAY .
{ Check activation of Secondary Air Injection (AIR) pump relay. See CHECKING ACTIVATION
OF SECONDARY AIR INJECTION (AIR) PUMP RELAY .
B. - If relay triggers, but Secondary Air Injection (AIR) pump does not run:
{ Check voltage supply of Secondary Air Injection (AIR) pump motor. See CHECKING
VOLTAGE SUPPLY FOR SECONDARY AIR INJECTION (AIR) PUMP MOTOR .
Checking voltage supply of Secondary Air Injection (AIR) pump relay
z Remove Secondary Air Injection (AIR) pump relay
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Fig. 117: Identifying Secondary Air Injection (AIR) Pump Relay Terminals In Relay Carrier
SECONDARY AIR INJECTION (AIR) PUMP RELAY CIRCUIT TEST - VOLTAGE SUPPLY
(TERMINAL 2)
Relay carrier below cover, left at bulkhead terminal Measure to
2 Engine Ground
z Perform the following tests marked with diamonds:

z Check fuse S131 (50 A) in main fuse box/battery.
z Check wire connection from B+ (terminal 30) to fuse S131 for Secondary Air Injection (AIR)
pump relay - J299- (below cover, left at bulkhead) for open circuit.
Fig. 118: Checking Fuse S131 (50 A) In Main Fuse Box/Battery

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SECONDARY AIR INJECTION (AIR) PUMP RELAY CIRCUIT TEST - VOLTAGE SUPPLY
(TERMINAL 6)
6 Engine Ground


z Check fuse S243 (in fuse holder, position 43)
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Fig. 120: Fuse Holder

z Check wire connection from B+ (terminal 30) to fuse S131 for Secondary Air Injection (AIR)
pump relay - J299- (below cover, left at bulkhead) for open circuit.
Checking activation of Secondary Air Injection (AIR) pump relay

z Remove Secondary Air Injection (AIR) pump relay.

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SECONDARY AIR INJECTION (AIR) PUMP RELAY CIRCUIT TEST - ACTIVATION

4 B+
z Initiate Output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) pump relay -
z LED must blink.

SECONDARY AIR INJECTION (AIR) PUMP RELAY CIRCUIT TEST - OPENS/SHORTS

Relay carrier below cover, left at bulkhead terminal VAG1598/31 test box socket
4 66
If no malfunctions are detected:
z Replace Secondary Air Injection (AIR) pump relay -J299-.
Checking voltage supply for Secondary Air Injection (AIR) pump motor
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z Remove center noise insulation (arrows).
Fig. 123: Removing Center Noise Insulation

z Remove connector for Secondary Air Injection (AIR) pump motor -V101-.
Fig. 124: Removing Connector For Secondary Air Injection (AIR) Pump Motor -V101-
z Connect VAG1527B voltage tester to connector terminals 1 and 2.

z Initiate Output Diagnostic Test Mode (DTM) and activate Secondary Air Injection (AIR) pump relay -
z LED must blink.

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z Check wire connection from connector at Secondary Air Injection (AIR) pump motor - V101- to
Secondary Air Injection (AIR) pump relay -J299- (in relay carrier below cover, left at bulkhead) for
open circuit:
z Check wire connection from connector at Secondary Air Injection (AIR) pump motor - V101- to Ground
point in engine compartment, left, for open circuit:
z Replace Secondary Air Injection (AIR) pump motor -V101-.
TANK VENTILATION, CHECKING
Evaporative Emission (EVAP) canister purge regulator valve -N80-, checking
z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31
{ or
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Checking for proper seal
When there is no current, the Evaporative Emission (EVAP) canister purge regulator valve - N80- is closed.
z Disconnect hoses from EVAP valve; harness connector remains connected.

z Attach auxiliary hose to one connection of EVAP valve.
z Initiate output DTM and activate Evaporative Emission (EVAP) canister purge regulator valve -N80-
(tank ventilation valve). See OUTPUT DIAGNOSTIC TEST MODE (DTM) .
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Fig. 126: VAG 1551 Scan Tool Display - Emission (EVAP) Canister Purge Regulator Valve
Valve must click...
...and must open and close (can be tested by blowing into auxiliary hose).
If valve does not click:
z Check internal resistance of EVAP valve.
If valve does not open and close properly:
z Replace Evaporative Emission (EVAP) canister purge regulator valve -N80-
z Disconnect connector at EVAP valve.
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Fig. 127: Checking EVAP Canister Purge Regulator Valve Internal Resistance

z Specified value: 22 - 30 ohm
z Replace Evaporative Emission (EVAP) canister purge regulator valve -N80-.
z See CHECKING VOLTAGE SUPPLY .
NOTE: Voltage is supplied to the EVAP valve via the Fuel Pump (FP) relay.
Test requirement
z Fuse for the EVAP valve OK
z Disconnect connector at EVAP valve.
Fig. 128: Identifying EVAP Canister Purge Regulator Valve Harness Connector Terminals
EVAP CANISTER PURGE REGULATOR VALVE CIRCUIT TEST - VOLTAGE SUPPLY

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1 Engine Ground

z LED must light.
z Check wire connection from terminal 1 to Fuel Pump (FP) relay via fuse for open circuit.
z Check Fuel Pump (FP) relay. See FUEL PUMP (FP) RELAY -J17-, CHECKING ACTIVATION .
If LED lights:
z Go to CHECKING ACTIVATION .
Checking activation
z Connect VAG1527B voltage tester to connector terminals 1 (B+) and 2.
z Initiate output DTM and activate Evaporative Emission (EVAP) canister purge regulator valve -N80-. See
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OUTPUT DIAGNOSTIC TEST MODE (DTM) .

z LED must blink
If LED does not blink or if it remains constantly lit:
EVAP CANISTER PURGE REGULATOR VALVE CIRCUIT TEST - ACTIVATION

2 64
ELECTRONIC ACCELERATOR (E-GAS) POWER CONTROL, CHECKING
E-Gas system, function
For E-Gas, the throttle valve is not operated by a cable from the accelerator pedal. There is no mechanical
connection between the accelerator pedal and the throttle valve.
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The position of the accelerator pedal is communicated to the Engine Control Module (ECM) via two sensors for
accelerator pedal position (variable resistances; stored in one housing) that are connected with the accelerator
pedal.
The accelerator pedal position (driver's intention) is a main input measure value for the ECM.
Operation of the throttle valve occurs via an electric motor (throttle valve actuator) in the throttle valve control
module. This is true across the entire engine speed and engine load spectrum.
The throttle valve is operated by the throttle valve actuator according to the instructions of the ECM.
With ignition switched on and engine off, the ECM activates the throttle valve actuator precisely according to
the sensor for accelerator pedal position. This means, if the accelerator pedal is depressed half way, the throttle
valve actuator opens the throttle valve to the same degree; i.e. throttle valve would be opened half way.
With engine running (under load), the ECM can open or close the throttle valve independently of the sensor for
accelerator pedal position.
This means, for example, that the throttle valve could be fully opened even though the accelerator pedal has
only been depressed half way. This has the advantage of preventing torque losses at the throttle valve.
In addition to this, it results in significantly better values relative to emissions and consumption under certain
load conditions.
The required engine torque can be achieved by the Engine Control Module (ECM) via the optimal combination
of throttle valve diameter and boost pressure.
It would be incorrect to think that "E-Gas" consists of only one or two components. E -Gas is much more of a
system containing all components that contribute to recognizing, controlling and monitoring the position of the
throttle valve, e.g. sensor for accelerator pedal position, throttle valve control module, EPC warning lamp,
Engine Control Module (ECM).
Electronic Power Control (EPC) warning lamp (malfunction indicator lamp for electronic accelerator -E-Gas) in
instrument cluster, significance
Location of EPC warning lamp
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Fig. 131: Location Of EPC Warning Lamp

Engine Control Module (ECM) checks all components that are important for function of the E -Gas system after
ignition is switched on.
During the test of these components, the ECM switches the EPC warning lamp on.
If malfunctions are recognized in the E-Gas system during operation of the engine, the ECM switches on the
EPC warning lamp in instrument cluster. (These malfunctions are listed in the DTC table). An entry is made in
DTC memory at the same time.
Malfunction light for power accelerator activation -K132-, checking
NOTE: The malfunction light for power accelerator activation -K132- is also called the
EPC warning lamp.
z VAG1594A
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Fig. 132: Identifying Special Tools And Equipment - VAG1594A

z VAG1598/31
Fig. 133: Identifying Special Tools And Equipment - VAG1598/31

Functional test of warning lamp

z EPC warning lamp must light up
A. - malfunction light for power accelerator activation (EPC warning lamp) -K132- does not light up
{ Connect VAG1598/31 test box at wiring harness to ECM, do not connect ECM. See WIRE AND
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{ Bridge sockets 1 and 48 of test box.
{ Switch ignition on.
z Warning lamp must light
If warning lamp does not light:
{ Switch ignition off.

{ Remove instrument cluster and check bulb and its voltage supply:
See INSTRUMENTS .
{ Check the following wire connection for open circuit and short circuit to B+:
INSTRUMENT CLUSTER CIRCUIT SPECIFICATION

Test box VAG1598/31 socket Instrument cluster ter
48 See appropriate System Wiring Diagrams a
{ Repair open circuit or short circuit if necessary.
{ Replace Engine Control Module (ECM). See ENGINE CONTROL MODULE (ECM)
B. - malfunction light for power accelerator activation -K132- remains lit after engine start
{ Check DTC memory of Engine Control Module (ECM).
If no DTCs are stored:
{ Connect VAG1598/31 test box at wiring harness to ECM, do not connect ECM. See WIRE AND
{ Check the following wire connection for short circuit to Ground:
INSTRUMENT CLUSTER CIRCUIT SPECIFICATION

Test box VAG1598/31 socket Instrument cluster ter
48 See appropriate System Wiring Diagrams a
{ Repair short circuit if necessary.
{ Replace Engine Control Module (ECM). See ENGINE CONTROL MODULE (ECM)
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Throttle valve control module -J338-, checking
The following components are located in the housing for the throttle valve control module:
z Throttle drive (power accelerator actuation) - G186-. (This is an electric motor that is activated by the
ECM. This electric motor opens the throttle valve against spring pressure.)
z Angle sensor -1- for throttle drive (power accelerator actuation) -G187-
z Angle sensor -2- for throttle drive (power accelerator actuation) -G188-
NOTE: z The housing for the throttle valve control module must not be opened.
z The angle sensors are designed as potentiometers (variable resistances).
They communicate the position of the throttle valve to the Engine Control
Module (ECM) fully independent of each other.
z The potentiometers cannot be mechanically adjusted. Adjustments are
made in Basic Setting (function 04) using the VAS5051 tester or VAG1551
Scan Tool.
Throttle valve control module, adaptation
During adaptation with ignition switched on and engine off, the Engine Control Module (ECM) learns the
various positions of the throttle valve. These positions are stored in the control module. The return
communication regarding the position of the throttle valve occurs via the two angle sensors for throttle drive.
An adaptation must always be performed when the throttle valve control module -J338- or the Engine Control
Module (ECM) are removed and installed (or replaced) or if voltage supply to the Engine Control Module
(ECM) is interrupted.
The learning process (adaptation) occurs:
z Via initiation of Basic Setting (function 04) display group 60 with ignition on.
z Automatically if the ignition is switched on for at least 6 seconds without operating starter and accelerator
pedal and the Engine Control Module (ECM) recognizes "adaptation required." (There will be no
notification of whether adaptation was successful or not however). Adaptation required is recognized if
stored voltage values from the angle sensors do not match actual measured voltage values within a certain
tolerance range.
NOTE: Engine will not start during automatic adaptation.
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Fig. 134: Identifying Special Tool VAS 5051

or
Requirements
z No DTCs in DTC memory; check DTC memory. See DIAGNOSTIC TROUBLE CODE (DTC)
z Engine not running, ignition switched on
z Accelerator pedal not depressed
z Coolant Temperature more than 5 °C but less than 100 °C. (Read Measuring Value Block, display group
4, display field 3)
z Intake Air Temperature (IAT) less than 100 °C (Read Measuring Value Block, display group 4, display
field 4)
z Supply voltage for ECM larger than 11 V; checking. See CONTROL MODULE VOLTAGE SUPPLY,
CHECKING .
Procedure
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Fig. 135: VAG 1551 Scan Tool Display - Throttle Valve Control Module, Adaptation (1 Of 4)
After pressing Q button, throttle valve actuator will be switched on mechanically (i.e. without current).
In this condition, the throttle valve will be drawn into an emergency position by a mechanical spring, which is
located in the throttle valve control module. The values that both angle sensors deliver in this emergency
position are stored by the Engine Control Module (ECM).
After this, the throttle valve is opened by a specific value. Once this value is reached, the throttle valve actuator
will be switched on again without current. Then the mechanical spring closes the throttle valve to the previously
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learned emergency position within a certain time (spring test).
Finally, the throttle valve is closed by the throttle valve actuator; the values that the angle sensors deliver in the
throttle valve control module are stored in the ECM.
If the ECM switches the throttle valve actuator during driving operation without current, this is indicated by a
heightened, uneven idle speed. The engine accepts gas only after great delay.
z Check specified values for throttle valve control module in display fields 3 and 4.
DISPLAY GROUP 60: ADAPTATION OF THROTTLE VALVE CONTROL MODULE

Display fields
1 2 3 4
Display group 60: Adaptation of throttle valve control module
Display xx % xx % --- ---
Indicated Throttle valve Throttle valve Adaptation step counter Adaptation
angle (angle angle (angle condition
sensor 1) sensor 2)
Work area min.: 0 % min.: 0 % 0-8 ADP running
max.: 100% max.: 100% ADP OK
ADP ERROR
Specified 3 - 93 % 97 - 3 % 8 ADP OK
value:
Note: During adaptation, adaptation If specified value is
step counter must run from 0 to 8. not obtained: see
(Some numbers may be skipped) Note below
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NOTE: The abbreviation "ADP" in display field 4 stands for "Adaptation."
NOTE: Possible reasons for the control module to abort the adaptation procedure:
z Throttle valve cannot be closed completely (e.g. contamination).

z Battery voltage is too low.
z Throttle valve control module or wire connection is malfunctioning.
z Engine is started during adaptation or accelerator pedal is operated.
z Tension of throttle valve housing (check bolts).
z End Basic Setting of engine by pressing --> button.
Angle sensor for throttle drive, checking
z VAG1526A
z VAG1594A
z VAG1598/31
or
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Test sequence
Angle sensor 1 for throttle drive (power accelerator actuation) -G187- and angle sensor 1 for throttle drive
(power accelerator actuation) - G188- inform the Engine Control Module (ECM) about the position of the
throttle valve. Both angle sensors are located in the throttle valve control module.
SYSTEM OR VAG1551 SCAN TOOL, CONNECTING AND SELECTING FUNCTIONS . Ignition
must remain switched on for this.
Fig. 140: VAG 1551 Scan Tool Display - Angle Sensor For Throttle Drive, Checking (1 Of 3)
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z Check specified value for E -Gas potentiometer voltages.
DISPLAY GROUP 62: E -GAS POTENTIOMETER VOLTAGES

Display fields
1 2 3 4
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Display group 62: E -Gas potentiometer voltages

Display xx % xx % xx % xx %
Indicated Throttle valve angle Throttle valve angle Sensor for Sensor 2 for
(angle sensor 1) (angle sensor 2) pedal position pedal position
Work area min.: 0 % min.: 0 % min.: 0 % min.: 0 %
max.: 100 % max.: 100 % max.: 100 % max.: 100 %
Specified value: 3 - 93 % 97 - 3 % 12 - 97 % 4 - 49 %
NOTE: Engine Control Module (ECM) calculates the voltage values of the angle
sensors in percent relative to 5 volts and displays these percentage values. (5
volts supply voltage represents 100 %).
z Observe display field 1 and 2.

z Slowly depress accelerator pedal completely.
Percent indication in display field 1 must climb uniformly. The tolerance range 3 - 93 % is not used completely
during this.
Percent indication in display field 2 must decrease uniformly. The tolerance range 97 - 3 % is not used
completely during this.
NOTE: z The reason that the indication in display field 1 climbs but the indication in
display field 2 decreases, is due to the inverse relationship of the
potentiometers (angle sensors) in the throttle valve control module.
z This means that the voltage of the one angle sensor runs toward 5 volts.
(The more the throttle valve is opened, the larger the voltage; percent
indication climbs).
z The voltage of angle sensor 2 runs from 5 volts toward 0 volts. (The more
the throttle valve is opened, the smaller the voltage; percent indication
decreases).
If indications do not resemble description:
z Check voltage supply and wire connections of throttle valve control module. See CHECK VOLTAGE
SUPPLY THROTTLE VALVE CONTROL MODULE . Pay particular attention to harness
connectors that could be loose or corroded.
z Check accelerator pedal position sensor. See ACCELERATOR PEDAL POSITION SENSORS,
CHECKING .
Check voltage supply throttle valve control module
z Disconnect connector from throttle valve control module.

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Fig. 143: Identifying Throttle Valve Control Module Harness Connector Terminals
THROTTLE VALVE CONTROL MODULE CIRCUIT TEST - VOLTAGE SUPPLY

Harness connector terminal Specified value
2 + Ground approx. 5 V
2+6 approx. 5 V
If specified values are obtained:
z Also check signal wires and activation wires of throttle valve actuator. See CHECKING WIRE
CONNECTIONS .
z Check wire connections from Engine Control Module (ECM) to throttle valve control module. See
CHECKING WIRE CONNECTIONS .
Checking wire connections
z Disconnect connector from throttle valve control module.

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Fig. 144: Identifying Throttle Valve Control Module Harness Connector Terminals
THROTTLE VALVE CONTROL MODULE CIRCUIT TEST - OPENS/SHORTS

1 92
2 83
3 117
4 84
5 118
6 91
If no malfunctions are found in wires:
z Replace throttle valve control module.
Accelerator pedal position sensors, checking
z VAG1526A
z VAG1594A
z VAG1598/31
or
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Test sequence
Both the Throttle Position (TP) sensor -G79- and the Sender -2- for accelerator pedal position - G185- are
located at the accelerator pedal and communicate the driver's intentions to the ECM completely independently
of each other. Both sensors are stored in one housing.
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Fig. 146: VAG 1551 Scan Tool Display - Accelerator Pedal Position Sensors, Checking (1 Of 3)
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z Check specified value for E -Gas potentiometer voltages.
DISPLAY GROUP 62: E -GAS POTENTIOMETER VOLTAGES

Display fields
1 2 3 4
Display group 62: E -Gas potentiometer voltages
Display xx % xx % xx % xx %
Indicated Throttle valve angle Throttle valve angle Sensor for Sensor 2 for
(angle sensor 1) (angle sensor 2) pedal position pedal position
Work area min.: 0 % min.: 0 % min.: 0 % min.: 0 %
max.: 100 % max.: 100 % max.: 100 % max.: 100 %
Specified value: 3 - 93 % 97 - 3 % 12 - 97 % 4 - 49 %
NOTE: Engine Control Module (ECM) calculates the voltage values of the angle
sensors in percent relative to 5 volts and displays these percentage values. (5
volts supply voltage represents 100 %).
z Observe display field 3 and 4.

z Slowly depress accelerator pedal completely.
Percent indication in display field 3 must climb uniformly. The tolerance range 12 - 97 % is not used
Percent indication in display field 4 must also climb uniformly. The tolerance range 4 - 49 % is not used
NOTE: The indicated value in display field 3 must always be approx. twice as large as
the value in display field 4.
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z Check voltage supply and wire connections of sensor for accelerator pedal position. See CHECKING
VOLTAGE SUPPLY OF THE SENSORS FOR ACCELERATOR PEDAL POSITION .
Checking voltage supply of the sensors for accelerator pedal position
z Disconnect harness connector for accelerator pedal position sensor.

Fig. 149: Identifying Accelerator Pedal Position Sensor Harness Connector Terminals
ACCELERATOR PEDAL POSITION CIRCUIT TEST - VOLTAGE SUPPLY

Harness connector terminal Specified value
1+5 approx. 5 V
2+3 approx. 5 V
z Also check signal wires.

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z Check wire connections from Engine Control Module (ECM) to sensors for accelerator pedal position.
z Connect VAG1598/31 test box at wiring harness to ECM, do not connect ECM, see WIRE AND
Fig. 150: Identifying Accelerator Pedal Position Sensor Harness Connector Terminals
ACCELERATOR PEDAL POSITION CIRCUIT TEST - OPENS/SHORTS

1 72
2 73
3 36
4 35
5 33
6 34
If no malfunctions are found in wires:
z Replace accelerator pedal position sensor.
See REMOVING AND INSTALLING ACCELERATOR PEDAL MODULE WITH THROTTLE

POSITION (TP) SENSOR -G79- AND SENDER -2-FOR ACCELERATOR PEDAL POSITION -G185- .
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NOTE: For vehicles with automatic/variable transmission, the kick down function must
be learned. See KICK DOWN FUNCTION, LEARNING .
Kick down function, learning
If the sensor for accelerator pedal position or the Engine Control Module (ECM) is replaced on a vehicle with
automatic transmission, the kick down function must be learned by the ECM.
Requirements
z No DTCs in DTC memory; check DTC memory. See DIAGNOSTIC TROUBLE CODE (DTC)
z Engine not running, ignition switched on.
Fig. 151: VAG 1551 Scan Tool Display - Kick Down Function, Learning (1 Of 4)
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NOTE: There will be a prompt: "Operate kick down"
z Depress accelerator pedal completely, past kick down point, and hold down.
NOTE: During the learning of the kick down point, the VAG1551 will display "Kick down
ADP in progress." After successful learning of kick down point, the VAG1551
will display "Kick down ADP OK."
z Check specified value in display field 4.

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DISPLAY GROUP 63: LEARNING KICK DOWN FUNCTION

Display fields
1 2 3 4
Display group 63: Learning kick down function
Display xx % xx % ---
Indicated Sensor for Sensor 2 Adaptation condition
pedal for
position pedal
position
Work area 0 - 100 % 0 - 100 % Kick down operate
ADP in progress
ADP OK
ADP ERROR
Specified 12 - 97 % 4 - 49 % Kick down ADP OK
value:
Note: If "ADP ERROR." is displayed: Check DTC memory. See
DIAGNOSTIC TROUBLE CODE (DTC) MEMORY,
CHECKING AND ERASING .
If specified value "ADP OK" is obtained:
z Press --> button.
z Press buttons -0- and -6- to select "end output."
VACUUM DIAGRAM
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1. - From fuel tank

2. - EVAP canister
z EVAP canister is located at rear, below at vehicle floor, below a cover
3. - Check-valve for EVAP canister

z Between EVAP canister and intake manifold before turbocharger
z Installed position (light/dark half): arrow points in direction of flow, as shown
4. - Turbocharger
5. - Pressure unit for boost pressure regulation
6. - Mechanical recirculation valve
7. - Brake booster
8. - Check-valve
z Between brake booster and intake manifold
9. - Wastegate Bypass Regulator Valve -N75-

11. - Air filter
12. - Pressure regulation valve for crankcase ventilation
13. - Vacuum reservoir
z Bolted on at cylinder head

z With Intake Air Temperature (IAT) sensor -G42-
16. - Check-valve
17. - Turbocharger boost pressure recirculation valve -N249-

19. - Crankcase ventilation
21. - Throttle valve control module -J338 -
22. - Charge Air Cooler
z With charge air pressure sensor -G31-
23. - Check-valve
z Between EVAP canister and intake manifold
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Fig. 155: Identifying Engine Vacuum Diagram

AUXILIARY SIGNALS, CHECKING
Engine speed signal, checking
NOTE: z The signal is generated by the engine speed (RPM) sensor -G28-
processed in the Engine Control Module (ECM) and directed to various
parts of the electronic system (for example, control module for A/C or
ABS / EDS) from terminal 37 of the ECM. Engine speed signal and wire
connections are monitored by these systems.
z Checking engine speed signal:
Consumption signal for board computer, checking
NOTE: z The consumption signal is calculated by the ECM from the injection time
and directed to the on board computer via terminal 81 of the ECM.
z Checking consumption signal:
See INSTRUMENTS .
Vehicle Speed Signal (VSS), checking
z VAG1526A
z VAG1527B
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z VAG1594A
z VAG1598/31
{ or

NOTE: z The vehicle speed signal is generated by the Vehicle Speed Sensor (VSS) -
G68- (at transmission) and processed in the instrument cluster.
z The processed signal enters at terminal 54 of the ECM and is used for idle
stabilization and tip-in shock reduction during shifting.
Test requirement
z Function and display of speedometer OK.
See INSTRUMENTS .
Test sequence
"address word" 01.See VAS5051 VEHICLE DIAGNOSTIC, TESTING AND INFORMATION
WARNING: To reduce the risk of accident during road tests, observe safety
precautions. See MULTIPORT FUEL INJECTION (MFI) .
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Fig. 157: VAG 1551 Scan Tool Display - Vehicle Speed Signal (VSS), Checking (1 Of 3)
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z Determine via road test whether vehicle speed is displayed in display field 3.
z If vehicle speed is not displayed, lift vehicle (if possible using a vehicle lift) until front left wheel is free.
z Connect VAG1527B voltage tester to sockets 3 (B+) and 54 (VSS) of VAG1598/31 test box.
z Switch ignition on and turn front left wheel by hand.
z LED must blink (very brief blink signal)
VEHICLE SPEED SIGNAL (VSS) CIRCUIT TEST - OPENS/SHORTS

Test box VAG1598/31 socket Instrument cluster terminal
54 See appropriate System Wiring Diagrams article.
A/C compressor switch-off, checking
z VAG1526A
z VAG1594A
z VAG1598/31
{ or
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NOTE: z The A/C compressor signal communicates to the ECM that the compressor
will be switched on in 140 ms.
z The ECM can switch off the A/C compressor via the same wire connection.
Engine Control Module (ECM) switches off A/C compressor:
z During hard acceleration (Wide Open Throttle 1st gear)

z In emergency mode (emergency operation)
z After initiating Basic Setting (function 04)
Test conditions
z A/C system OK
z Not DTC in DTC memory of Engine Control Module (ECM)
z Vehicle at room temperature (warmer than +15 °C)
Test sequence
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Fig. 161: VAG 1551 Scan Tool Display - A/C Compressor Switch-Off, Checking (1 Of 3)
Indicated on display: (1 - 4 display fields)
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z Switch A/C system off.

z Specified value in display field 4: Compr. OFF
z Switch A/C system on using "Auto" button and adjust A/C system to maximum cooling or heating power.
Compressor must run.
z Specified value in display field 4: Compr. ON

z Fully depress accelerator pedal abruptly and then release (brief acceleration).
z Specified value in display field 4: Display switches for a few seconds from "Compr. ON" to
"Compr. OFF" (compressor switch - off for vehicle acceleration)
A/C CONTROL HEAD -E87- TERMINAL SPECIFICATION

Test box VAG1598/31 socket A/C control head -E87- terminal

z If there are no malfunctions in the wiring, check function of A/C system.
See ON BOARD DIAGNOSTIC (OBD) .
Brake light switch and brake pedal switch, checking
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z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31
or

Test sequence
NOTE: For safety reasons, the instruction from the accelerator pedal sensor
(potentiometer) to the ECM to open the throttle valve is suppressed when brake
is being operated. This requires the brake light switch signal and also the brake
pedal switch signal in the control module. If brake pedal is operated with
accelerator pedal constantly depressed, engine is immediately regulated down
to idle speed. A malfunctioning switch can lead to undesired regulation.

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Fig. 165: VAG 1551 Scan Tool Display - Brake Light Switch And Brake Pedal Switch, Checking (1 Of 3)
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z Check brake light/brake pedal switch in display field 2.
DISPLAY GROUP 66: SIGNALS TO ENGINE CONTROL MODULE (ECM)

Display fields
1 2 3 4
Display group 66: Signals to Engine Control Module (ECM)
Display xxx km/h XXXX xxx km/h XXXX
Indicated ACTUAL Switch positions SPECIFIED Switch
speed speed positions
Work area XX00 XX11
Specified XX00 (with brake pedal not
value: operated)
XX11 (with brake pedal operated)
Note: Value: X = no significance.
Switch points slightly offset
Check switch
z Disconnect harness connector at brake light/brake pedal switch.
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Fig. 168: Identifying Connector Terminals At Brake Light/Brake Pedal Switch

z Connect multimeter between terminals 1 and 4 for resistance measurement.

z Specification: INFINITY ohm (no continuity)
z Depress accelerator pedal.

z Specified value: approx. 0 ohm

z Depress accelerator pedal.

z Specification: INFINITY ohm(no continuity)
z Replace brake light/brake pedal switch.
BRAKE LIGHT SWITCH AND BRAKE PEDAL SWITCH CIRCUIT TEST - VOLTAGE
SUPPLY (TERMINAL 1)
1 Chassis Ground
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Fig. 169: Identifying Brake Light/Brake Pedal Switch Harness Connector Terminals
z LED must light.
BRAKE LIGHT SWITCH AND BRAKE PEDAL SWITCH CIRCUIT TEST - VOLTAGE
SUPPLY (TERMINAL 2)
2 Chassis Ground

z LED must light
z Check wire connection from terminal 1 or 2 of connector for open circuit and short circuit to Ground:
Checking activation
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Fig. 170: Identifying Brake Light/Brake Pedal Switch Harness Connector Terminals
BRAKE LIGHT SWITCH AND BRAKE PEDAL SWITCH CIRCUIT TEST - ACTIVATION
3 55
4 56
Clutch vacuum vent valve switch -F36-, checking
z VAG1526A
z VAG1527B
z VAG1594A
z VAG1598/31
{ or
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NOTE: This signal is used to prevent engine speed swing oscillations and tip -in shock
during clutch release and is required by the cruise control system.
Test sequence
Fig. 172: VAG 1551 Scan Tool Display - Clutch Vacuum Vent Valve Switch, Checking (1 Of 3)
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z Check Clutch Pedal Position (CPP) switch in display field 2.
DISPLAY GROUP 66: SIGNALS TO ENGINE CONTROL MODULE (ECM)

Display fields
1 2 3 4
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Display group 66: Signals to Engine Control Module (ECM)

Display xxx km/h XXXX xxx km/h XXXX
Indicated ACTUAL Switch positions SPECIFIED Switch
speed speed positions
Work area X0XX X1XX
Specified X0XX
value: (with clutch pedal not operated)
X1XX
(with clutch pedal operated)
Note: Value: X = no significance (switch points
are slightly offset)
If indications do not resemble description, go to CHECK SWITCH .
Check switch
z Disconnect harness connector at Clutch Pedal Position (CPP) switch.
Fig. 175: Identifying Connector Terminals At Clutch Pedal Position (CPP) Switch

z Depress clutch pedal.

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z Check adjustment of Clutch Pedal Position (CPP) switch
or
z Replace Clutch Pedal Position (CPP) switch.
If specified value is obtained, go to CHECKING VOLTAGE SUPPLY .
CLUTCH VACUUM VENT VALVE SWITCH CIRCUIT TEST - VOLTAGE SUPPLY

1 Chassis Ground
Fig. 176: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals

z LED must light.
z Check wire connection from terminal 1 of connector to Fuel Pump (FP) relay via fuse for open circuit and
short circuit to Ground.
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Checking activation
Fig. 177: Identifying Clutch Vacuum Vent Valve Switch Harness Connector Terminals
CLUTCH VACUUM VENT VALVE SWITCH CIRCUIT TEST - ACTIVATION

2 39
Pressure switch/power steering -F88-, checking
z VAG1526A
z VAG1594A
z VAG1598/31
or
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The pressure switch for power steering is used for idle stabilization when steering is turned to full stop (left or
right).
Test sequence
Fig. 179: VAG 1551 Scan Tool Display - Pressure Switch/Power Steering, Checking (1 Of 3)
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z Check pressure switch/power steering in display field 4.
DISPLAY GROUP 56: IDLE STABILIZATION WITH ENGINE AT IDLE AND OPERATING
TEMPERATURE
Display fields
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1 2 3 4
Display group 56: Idle stabilization with engine at idle and operating temperature
Display xxx /min xxx /min x.x % XXXXX
Indicated Engine speed Engine speed Idle control Operating conditions
(actual) (specified) torque change
Work area 0XXXX
1XXXX
Specified 0XXXX
value: (with steering wheel straight
ahead or turned slightly)
1XXXX (with steering wheel at
full stop)
Note: Value: X = no significance
If indications do not resemble description, go to CHECK SWITCH .
Check switch
z Disconnect harness connector at pressure switch/power steering -F88 -, at power steering pump.
Fig. 182: Identifying Power Steering Pump Pressure Switch

z Connect multimeter at switch for resistance measurement.

z Start engine.
z Turn steering as far to right or left as possible.

If indication does not change:

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z Replace pressure switch/power steering -F88 -.
If indication changes:
z See CHECKING WIRE CONNECTIONS .
Fig. 183: Identifying Power Steering Pump Pressure Switch Harness Connector Terminals
POWER STEERING PUMP PRESSURE SWITCH CIRCUIT TEST - OPENS/SHORTS

1 49
2 50
Wiring for fuel level signal, checking
NOTE: z The Engine Control Module (ECM) receives the fuel level signal from the
instrument cluster.
z The processed signal enters at terminal 30 of the ECM and is used to
determine the cause of certain recognized malfunctions (for example,
combustion misfires).
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z Check wire connection from terminal 30 at test box to instrument cluster for open circuit and short circuit
to B+/Ground.
Data exchange, Motronic / ABS (CAN-bus), checking
z VAG1526A
z VAG1594A
z VAG1598/31
{ or

Checking
z Check DTC memory of ABS control module (w/EDL).
If there is a DTC related to the CAN -bus/databus power train stored:
ABS CONTROL MODULE (W/EDL) -J104 - OR DATA-BUS CAPABLE SYSTEMS

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TERMINALS SPECIFICATION
Test box VAG1598/31 ABS control module (w/EDL) -J104 - or DATA-bus capable systems
socket Terminals
60
77
79
z Replace ABS control module or Engine Control Module (ECM) as a test.
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2000 Audi TT

2000-2004 ENGINE PERFORMANCE

Multiport Fuel Injection (MFI), 1.8L Turbo, ATC - TT

MULTIPORT FUEL INJECTION (MFI)

Scan Tool (ST) and test equipment safety precautions

WARNING: Use of Instrument in Audi TT Coupe:

z Place Instrument in rear seating area and secure by available safety

z Instrument Operator must wear safety belt.

Use of Instrument in Audi TT Roadster:

Residual pressure after 10 min. minimum 1.5 bar positive pressure

Component locations, overview

The following list pertains to Fig. 1 .

1. - Leak Detection Pump (LDP) - V144-

See CHARGE AIR PRESSURE CONTROL VALVE -N75-, TESTING .

12. - Malfunction light for power accelerator activation -K132-

z Component location, see COMPONENT LOCATION, MALFUNCTION LIGHT FOR

14. - Mass Air Flow (MAF) sensor -G70-

z Component location, see COMPONENT LOCATION, 3-PIN HARNESS CONNECTORS

z For Knock Sensor (KS) 1 - G61-

z For Engine Speed (RPM) sensor -G28-

z For Knock Sensor (KS) 2 - G66-

21. - Secondary Air Injection (AIR) solenoid valve -N112-

See SECONDARY AIR SYSTEM, COMPONENTS AND FUNCTION .

25. - Pressure switch/power steering -F88 -

See CHARGE AIR PRESSURE SENSOR -G31-, TESTING .

z Headlight must be removed in order to access charge air pressure sensor.

See HEADLIGHTS or HEADLIGHTS WITH HIGH INTENSITY GAS DISCHARGE (HID)

Fig. 1: Identifying Multiport Fuel Injection (MFI) Component Locations

Oxygen sensors and protective cover

Fig. 2: Identifying Oxygen Sensors And Protective Cover

Black and brown connectors

Fig. 3: Locating Black And Brown HO2S Connectors

Component location, exhaust warning lamp -K83-

Fig. 6: Exhaust Warning Lamp - K83- (MIL)

Component location, malfunction light for power accelerator activation -K132-

Fig. 7: Malfunction Light For Power Accelerator Activation -K132-

Component location, clutch vacuum vent valve switch -F36-

Fig. 8: Locating Clutch Vacuum Vent Valve Switch -F36 -

Component location, 3-pin harness connectors

1. - For Knock Sensor (KS) 1 -G61-

Fig. 9: 3 -Pin Harness ConnectorLocations

Component location, pressure switch/power steering -F88-

Fig. 10: Locating Pressure Switch/Power Steering -F88 -

Air filter, disassembling and assembling

The following list pertains to Fig. 11 .

10. - Air intake connection

Fig. 11: Exploded View Of Air Filter Assembly

Wire and component test using VAG1598/31 test box

Special tools and equipment

Fig. 12: Identifying Special Tools And Equipment

VAG1598/31 test box

WARNING: To reduce the risk of damage to electronic components, switch on power

z Switch ignition off.

Fig. 13: Connecting VAG1598/31 Test Box To Connector Of Wiring Harness

z Perform test as described in relevant repair sequence.

Procedure after voltage supply is interrupted

Special tools and shop equipment

z VAS5051 with VAG5051/1

Fig. 14: Identifying Special Tools - VAS5051

z VAG1551 with VAG1551/3B

Perform the following steps after an interruption in the voltage supply.

Engine Control Module (ECM) (without metal anti-theft housing), replacing

Removing Engine Control Module (ECM)