D3E80270E90-Motronic Injection and Ignition System (5-Cyl 4-Valve)

Service
Workshop Manual
Passat 1997 ➤
Motronic injection and ignition system (5-cyl. 4-valve)
Engine ID AZX
Edition 11.2009
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Repair Group
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01 - Self-diagnosis
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24 - Mixture preparation - injection
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28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E80270E90

Passat 1997 ➤
Motronic injection and ignition system (5-cyl. 4-valve) - Edition 11.2009
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General information on self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Significance of EPC warning lamp (fault lamp for electronic power control) in dash panel
insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Significance of exhaust emissions warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Connecting the fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Reading and erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Fault table: from V.A.G code 16395 / SAE P0 or P2 codes . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Fault table: from V.A.G code 17455 / SAE P1 or P3 codes . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Performing final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Reading out readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Generating readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 Evaluating measured value blocks, display groups 0...8 -basic functions- . . . . . . . . . . . . 56
7 Evaluating measured value blocks, display groups 10...29 -Ignition- . . . . . . . . . . . . . . . . . . 61
8 Evaluating measured value blocks, display groups 30...33,A99 G. V-Lambda
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9 Evaluating measured value blocks, display groups yV
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10 Evaluating measured value blocks, displayogroups ris
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .au.th. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r .a . 75
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11 Evaluating measured value blocks, display groups 90...95 -Enhanced performance- . . . . 76
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12 Evaluating measured value blocks, display groups 120...126 -Communication- . . . . . . . . 78
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24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
spec
1.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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1.3 Removing and installing parts of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.4 Dismantling and assembling intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Dismantling and assembling fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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1.6 Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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1.8 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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2.1 Checking Lambda probe heating for Lambda probes before catalytic converter . . . . . . . . 91
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2.2 Checking Lambda probe heating for Lambda probes after catalytic converter . . . . . . . . . . 93
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2.3 Checking air mass meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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2.4 Checking throttle valve control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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2.5 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t. Cop py
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2.6 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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2.7 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by c 112
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2.8 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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2.9 Checking injectors for leaks and quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.10 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Contents i
Passat 1997 ➤
2.11 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

2.12 Checking intake system for leaks (unmetered air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.1 Idling check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.2 Adapting idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.3 Checking Lambda probe and Lambda control before catalytic converter . . . . . . . . . . . . . . 128
3.4 Checking Lambda probe and Lambda control n Aafter
G. Volkcatalytic
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3.5 Checking Lambda probe ageing of Lambda lkswage probe 1 before catalytic does
not converter . . . . . . . . 134
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3.6 Checking Lambda probe ageing ris
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3.7 Checking engine operatingaustatuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . e. o.r a. . . . . . . . . . . .
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4 Engine control unit . . . . s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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4.1 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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4.2 Procedure after voltage supply open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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4.3 Renewing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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4.4 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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4.5 Erasing learnt values of control unit for engine electronics . . . . . . . . . . . . . . . . . . . . . . . . 142
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4.6 Adapting engine control unit to throttle valve control module . . . . . . . . . . . . . . . . . . . . . . . . 143
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4.7 Teaching-in kick-down point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.1 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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5.2 Checking signals from and to air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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5.3 Checking signal from clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.4 Checking signal from brake light switch and brake pedal switch . . . . . . . . . . . . . . . . . . . . 149
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5.5 Checking driving range signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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5.6 Checking kick-down point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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5.7 Checking matching resistor for data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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1 Repairing ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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1.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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1.2 Removing and installing parts of ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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1.4 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote AG.
157
1.5 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.6 Checking ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.7 Checking knock sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.8 Checking misfiring detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ii Contents
Passat 1997 ➤
01 – Self-diagnosis
1 General information on self-diagno‐
sis
1.1 Features of self-diagnosis

The Motronic control unit -J220- is equipped with a fault memory.
If faults occur in the sensors and components being monitored,
they will be stored in the fault memory together with an indication
of the type of fault.
After evaluating the information, the engine control unit decides
between 259 different fault codes ⇒ Fault table Page
⇒ page 10 or ⇒ page 17 and stores these until the contents
of the fault memory are cleared.
Faults which occur temporarily (sporadically), are printed out with
the addendum “sporadic fault”. These faults are indicated on dis‐
play by the addendum “/SP”. The cause of sporadic faults can be
e.g. a loose contact or a temporarily open circuit. If a sporadic
fault does not occur again within 40 warm-up phases (engine start
below 50° C coolant temperature - switched off above 72° C), it
will be cleared from theenfault
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All values learnt by the engine control unit will be cleared when
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disconnected. The contents of the fault memory will remain intact.

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When the engine is subsequently started, idling may be rough for

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a brief period. In this case leave the engine running for a few mi‐
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voltage supply ⇒ page 139 .

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The fault memory must be erased after the faults have been elim‐
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General information on self-diagnosis can be found in the instruc‐

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1.2 Significance of EPC warning lamp (fault

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“EPC” is an abbreviation and stands for Electronic Power Control.
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1. General information on self-diagnosis 1

Passat 1997 ➤
Fitting location of EPC warning lamp

If a fault is detected in the electronic power control system while
the engine is running, the instrument cluster switches on the EPC
lamp. (These faults are identified in the fault table). At the same
time an entry is stored in the fault memory of the engine control
unit.
Functional check:
– Switch ignition on: the EPC warning lamp must light up.
EPC warning lamp does not light up with ignition switched on:
– Check instrument cluster and EPC warning lamp as follows:
⇒ Electrical system self-diagnosis; Rep. Gr. 01
EPC warning lamp lights up with ignition switched on:
– Start engine and run at idling speed: EPC warning lamp must
go out after a few seconds.
If the EPC warning lamp does not go out:
– Read fault memory, if necessary, repair any faults and then
clear fault memory ⇒ page 8 , Reading and clearing fault
memory.
– Read readiness code out ⇒ page 43 . If the fault memory has
been cleared or the engine control unit was disconnected from
the continuous positive supply, you have to regenerate the
readiness code ⇒ page 44 .
1.3 Significance of exhaust emissions warn‐

ing lamp
If faults are detected by the engine controlgeunit,
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2 Rep. Gr.01 - Self-diagnosis

Passat 1997 ➤
Exhaust emissions warning lamp fitting location
Note
♦ The exhaust emissions warning lamp will either flash or light

up constantly. Fault memory has to be interrogated in any case
⇒ page 8 .
♦ Flashing: a fault has occurred which, under the current driving
conditions, will cause damage to the catalytic converter. In this
case, the vehicle may only continue to be driven at reduced
output!
♦ Constantly lit: a fault detrimental to the exhaust emissions has
occurred. Read fault memory for engine control unit or auto‐
matic gearbox.
♦ Fault memory must be read if a driving behaviour problem or
a customer complaint exists and the exhaust emissions warn‐
ing lamp does not light up, as faults which do not immediately
activate the exhaust emissions warning lamp may also be n AG. Volkswagen AG do
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Functional check: tho
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– Switch ignition on: the exhaust emissions warningss lamp must
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Exhaust emissions warning lamp does not light up with ignition
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– Check instrument cluster and exhaust emissions warning
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lamp as follows: ⇒ Electrical system self-diagnosis; Rep. Gr.
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01 .
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Exhaust emissions warning lamp lights up with ignition switched
on:
– Start engine and run at idling speed: exhaust emissions warn‐
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ing lamp must go out after a few seconds.
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1.4 Technical data of self-diagnosis his

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Control unit identification

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The control unit version is displayed when the -V.A.G 1551- fault Cop py
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VAS 5051- tester is connected and the control unit for engine
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Technical data
Engine code AZX
System designation Motronic ME7.1
Emissions fulfil EU4 standard
Self-diagnosis OBD
Final control diagnosis yes
Method of data transfer to -V.A.G 1551/1552- Rapid data transfer
Fault memory Non-volatile memory 1)
Learnt value memory Volatile memory 2)
Lambda control 2 probes

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Passat 1997 ➤ thor eo
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Motronic injection and ignition
ss a system (5-cyl. 4-valve) - Edition 11.2009 c
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Engine code AZX
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Knock control 2 knock sensors
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Variable intake manifold yes
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Camshaft timing control hole
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Charge pressure control no
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Secondary air system yes
1) Independent of voltage supply.
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2) Values are cleared when voltage supply is interrupted.
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Functions which can be selected when using fault readers -
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V.A.G 1551/1552- or -VAS 5051-

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The prerequisites for selecting the desired functions can be de‐
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Function Prerequisite
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Functions on -V.A.G 1551/1552- or on - Engine stationary, Engine running at Vehicle being driv‐
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01 Read control unit version opyri
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yes
02 Read fault memory yes3) yes yes
c by lksw
cted agen
Prote AG.
03 Final control diagnosis yes no no
04 Basic setting4) yes no5) no5)
05 Clear fault memory yes yes yes
06 End output yes yes yes
07 Code control unit yes no no
08 Reading measured value block yes yes yes
10 Adaption yes yes no
15 Reading out readiness code yes yes yes
3) Only carry out with ignition switched on, when engine does not start (operate starter for at least 6 seconds first).
4) Must be carried out after the following: Renewing engine control unit, throttle valve control module, engine or disconnecting battery.
5) Yes, for λ regulation adaption in basic setting (display group 032) and generation of the readiness code.
1.5 Connecting the fault reader

All functions previously carried out with -V.A.G 1551- or -
V.A.G 1552- can also be carried out with new tester -VAS 5051-
in vehicle self-diagnosis operating mode. ⇒ Operating instruc‐
tions for vehicle diagnosis, testing and information system
VAS 5051.
Special tools and workshop equipment required

Passat 1997 ➤
♦ -VAS 5051- Vehicle diagnosis, testing and information system
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Test prerequisites: AG. Volkswagen AG d
agen oes
olksw not
V gu
• All fuses must be d OK.
by ara
rise nte
ho eo
• The batteryauvoltage
t must be at least 11.5 V. ra
c
ss
• Earth connections between engine (on gearbox bell housing)
ce
e
nl
pt
du
and body (next to battery) OK.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Connecting -VAS 5051- : rrectness of i
– Connect diagnosis cable connector on to diagnosis connec‐

tion.
l purpos
– Depending upon desired function: switch ignition on or start

engine ⇒ page 4 , “Selectable functions” table.
nf
ercia
or
Selecting operating mode:

m
m
atio
om
– Press button on display for “Vehicle self-diagnosis”.

n in
or c
thi
e
Selecting vehicle system:

t
sd
iva
o
r
rp
cu
– Press button “01 - Engine electronics” on display.

o
m
f
en
ng
t.
yi
The control unit identification and engine control unit coding are
Co
op py
indicated on display.
t. C rig
gh ht
pyri by
Vo
o
If the coding does not correspond to the equipment in the vehicle:
c by lksw
cted agen
Prote AG.
– Check control unit coding, code control unit if necessary
⇒ page 141 .
Selecting diagnostic function:
All the available diagnosis functions are shown on the display.
– Press key on display for the desired function.
Note
♦ The display fields will be displayed from top to bottom in func‐

tions 04 - Basic settings or 08 - Read measured value block.
♦ The following test sequences are described for the -
V.A.G 1551- fault reader.
Connecting -V.A.G 1551- :

Passat 1997 ➤

♦ -V.A.G 1551- Fault reader
♦ -V.A.G 1551/3- Line
Note
Vehicle system tester -V.A.G 1552- can be used instead of fault

reader -V.A.G 1551- , however a print-out is not possible.
Procedure
– Connect fault reader -V.A.G 1551- with cable -V.A.G 1551/3- .
– Depending upon desired function: switch ignition on or start
engine ⇒ page 4 , “Selectable functions” table. G. Volkswage A n AG d
agen oes
olksw not
yV gu
db ara
Note rise nte
tho eo
s au ra
c
♦ If the display remains blank, diag‐ check
s voltage supply for
ce
e
nostic connector according to fault finding programme:⇒ Cur‐

nl
pt
du
an
rent flow diagrams, Electrical fault finding and Fitting locations
itte
y li
erm
ab
♦ If the display does not indicate as described in the work se‐
ility
ot p
quence:⇒ Fault reader operating instructions
wit
, is n
h re
♦ If due to an input error “fault in data transfer!” is displayed, pull
hole
spec
cable off fault reader, reconnect and repeat work steps.
es, in part or in w
t to the co
Indicated on display: V.A.G SELF-DIAGNOSIS HELP
1 - Rapid data transfer
rrectness of i
Displayed alternatingly. V.A.G SELF-DIAGNOSIS HELP
l purpos
2 - Flash code output
– Operate fault reader taking into account the information on the nform
ercia
display:
m
at
– Press key 1 for “Rapid data transfer”.

om
ion
c
in t
– Press keys 0 and 1 for address word “Engine electronics” and

or
his
e
confirm entry with Q key.

at
do
priv
cum
or
The control unit identification and coding are indicated on display,

f
en
066906032J MOTRONIC ME7.1 G 001 ->

ng
e.g.:
t.
yi Coding 00131 Co WSC 00000
Cop py
t. rig
In vehicles as of model year 2001, the 17-digit chassis number gh ht
yri byWVWZZZ3BZ1E035486 VWZ7Z0Y2574101
and the 14-digit immobiliser ID number are additionally displayed, cop Vo
by lksw
cted
e.g.:
agen
Prote AG.
♦ 066 906 032 J = part No. of the control unit (for latest control
unit version, see parts catalogue)
♦ MOTRONIC ME7.1 = system designation (Motronic)
♦ G = cruise control system
♦ 001 = programme version number
♦ Coding 00131 = control unit coding, coding variants of engine
control unit ⇒ page 141 .
♦ WSC 00000 = workshop code from -V.A.G 1551- , of the work‐
shop which last carried out coding. (If the factory coding has
not been changed, WSC 00000 appears)

Passat 1997 ➤
Note
If the display does not correspond to the control unit version for
the vehicle, renew control unit ⇒ page 140 .
Incorrect engine control unit coding leads to:

♦ Engine running faults (gear change jerks, load change jerks,
etc.) Volkswa
AG. gen AG
agen does
♦ Increased fuel consumption yV
olksw not
gu
db ara
♦ Increased exhaust emissions rise nte
tho eo
au ra
♦ Storage of non-existent
s faults in fault memory
s c
ce
le
un
pt
♦ Functions will not be performed (Lambda regulation, activation
an
d
itte
of the activated charcoal filter system, etc.).
y li
erm
ab
ility
♦ Reduced gearbox life
ot p
wit
is n
If the coding does not correspond to the equipment in the vehicle:
h re
ole,
spec
– Check control unit coding ⇒ page 141 , coding engine control
unit.
t to the co
– Press → button.
rrectne
Indicated on display: Rapid data transfer HELP
Select function XX
ss
– Further measures see repair procedures.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
2 Fault memory
AG. Volkswagen AG d
agen oes
olksw not
yV gu
2.1 Reading and erasing fault memory
d b ara
ise nte
or eo
h
ut ra
Special tools and sworkshop
s a equipment required c
ce
le
♦ Fault reader -V.A.G 1551- (or vehicle system tester -

un
pt
an
d
V.A.G 1552- ) with cable -V.A.G 1551/3-

itte
y li
rm
ab
Procedure
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
All functions which were previously performed with -
V.A.G 1551/1552- can also be performed with the new tester -
VAS 5051- .
rrectness of i
l purpos
– Connect fault reader -V.A.G 1551- (V.A.G 1552) and select

engine control unit with “address word” 01. Engine must be
idling. (Connecting fault reader and selecting engine electron‐
nform
ercia
ics control unit ⇒ page 4 .)

m
a
Only when engine does not start:
com
tion in
r
– Actuate starter for approx. 6 seconds. Do not then switch off

te o
ignition. thi
s
iva
do
r
rp
cum
– Switch on fault reader printer with the print key. The warning
fo
en
ng
lamp in key must light up.

t.
yi Co
Cop py
.
Indicated on display:
ht rig
rig ht
py by Rapid data transfer HELP
by co Vo
lksw Select function XX
cted agen
Prote AG.
– Operate fault reader taking into account the information on the
display:
– Press keys 0 and 2 for function “Read fault memory” and
The number of faults stored or “No fault recognised!” will be X Faults recognised!
shown on the display.
Note
If no fault is stored, do not unnecessarily erase the fault memory,

as the readiness code is otherwise reset.
If one or more faults are stored:
The stored faults will be displayed and printed out one after the
other.
When the stored faults have been printed out, the display will Rapid data transfer HELP
show: Select function XX
– Press keys 0 and 5 for function “Erase fault memory” and

Indicated on display: Rapid data transfer ->
Fault memory is cleared!

Passat 1997 ➤
Note
If the ignition is switched off between “Read fault memory” and

“Clear fault memory” the fault memory will not be cleared.
– The readiness code must be regenerated if the fault memory

has been erased ⇒ page 44 .
Select function XX
– Press buttons 0 and 6 for function “End output” and confirm

entry with Q button.
– Rectify faults printed out using fault table: SAE P0 or P2 codes
⇒ page 10 , SAE P1 or P3 codes ⇒ page 17
Automatic test sequence
During test and assembly work, faults may also be recognised by
other control units e.g. connectors disconnected. Therefore read
and clear the fault memories of all control units on completion. To
do this:
– Press key 0 twice for address word “Automatic test sequence”
and confirm entry with Q key. The -V.A.G AG.1551-
Volkswatransmits
gen AG all
agen does
known address words one afteryV
olthe
ksw other. not
g b ua
ed ran
When a control unit answersho
riswith its identification the number of tee
stored faults appears onathe
ut display or “No fault recognised”. or
ac
ss
Any system faults that are stored will be displayed one after the
ce
le
un
pt
other and printed out. The -V.A.G 1551- will then transmit the next
an
d
itte
y li
address word.
rm
ab
pe
ility
The automatic test sequence has ended when following is indi‐

ot
V.A.G SELF-DIAGNOSIS HELP

wit
cated on display:
, is n
1 - Rapid data transfer*

h re
hole
spec
Displayed alternatingly. V.A.G SELF-DIAGNOSIS HELP

es, in part or in w
2 - Flash code output*

t to the co
– Clear all fault memories and then carry out a road test.
Observe applicable safety precautions during road test
rrectness of i
⇒ page 89 .
l purpos
During the road test, the following operating conditions must be

met:
nform
ercia
• The coolant temperature must exceed 85°C.

m
a
com
ti
• When the temperature is reached, the operating conditions

on in
idling, part throttle, full throttle and overrun must be attained

r
te o
thi
several times.
s
iva
do
r
rp
• At full throttle, the speed must exceed 3500 rpm.

um
fo
en
ng
t.
yi
– Again read the fault memories of all control units using the
Co
op py
“automatic test sequence”.
t. C rig
gh ht
pyri by
Vo
If no fault is stored:
o
by c lksw
cted agen
Prote AG.
Select function XX

– Switch off ignition.
2. Fault memory 9
Passat 1997 ➤
2.2 Fault table: from V.A.G code 16395 /

SAE P0 or P2 codes
Note
♦ The fault code overview is listed according to SAE or V.A.G

code.
♦ “EPC ”-relevant faults are also indicated by the EPC warning
lamp (“EPC warning lamp”) in the dash panel insert.
n AG. Volkswagen AG ge does
swa
♦ Explanations on the
by fault types (e.g. “open circuit/short
Vol
k not
gu circuit
to earth”): ⇒ Fault
ris reader operating instructions
ed
a ran
tee
ho
ut o
♦ If components are
indicated as faulty: First check the
ss
a wiring r ac
and connectors to these components as well as the system
ce
le
earth connections referring to current flow diagram. Only when

un
pt
an
d
no fault can be located here should the component be re‐

itte
y li
rm
newed. This is particularly relevant if faults are output as
ab
pe
ility
“sporadic” (SP).
ot
wit
, is n
♦ After fault rectification, the fault memory must be erased
h re
hole
⇒ page 8 and the readiness code regenerated ⇒ page 44 .
spec
es, in part or in w
t to the co
Output on the V.A.G. 1551 printer, e.g.:
16497 P0113 035
Intake air temperature sender -G42- rrectness of i
l purpos
Signal too large

Sporadic fault
nform
ercia
Explanation:
m
a
com
tion in
♦ 16497 = Fault code

r
te o
thi
s
♦ P0113 = additional fault code

iva
do
r
rp
cum
♦ 035 = Fault type as a number

fo
en
ng
t.
yi Co
♦ Intake air temperature sender -G42- = faulty current path or Cop py
t. rig
fault location opyri
gh by
Vo
ht
c lksw
♦ Signal too high = Fault type as text
by
cted agen
Prote AG.
♦ Sporadic faults = Faults that are not always present e.g. loose
contact
Explanation of the SAE fault codes:
System type:
♦ Pxxxx = fault codes for the drive train
Standard code:
♦ P0xxx = fault codes defined according to SAE with defined
fault texts
♦ P1xxx = fault codes additionally offered by the manufacturer
♦ P2xxx = fault codes defined according to SAE with defined
fault texts as of model year 2000
♦ P3xxx = exhaust emission-relevant fault codes additionally of‐
fered by the manufacturer as of model year 2000
System group:
♦ Px1xx = fuel and air supply measurement
♦ Px2xx = fuel and air supply measurement

Passat 1997 ➤
♦ Px3xx = ignition system

♦ Px4xx = additional exhaust emission regulation
♦ Px5xx = speed and idling speed regulation
♦ Px6xx = control unit and output signals
♦ Px7xx = gearbox AG. Volkswagen AG d
agen oes
lksw not
♦ Px8xx = gearbox d byV
o gu
ara
ise nte
r
♦ Px9xx = control units, input and output signals
ut
ho eo
ra
s a c
s
Fault code Fault text Fault remedy
ce
le
un
pt
SAE V.A.G
an
d
itte
y li
rm
ab
P0011 16395 Bank1, camshaft timing advance
pe
ility
Specification not reached
ot
wit
, is n
P0012 16396 Bank1, camshaft timing retard – Checking variable valve tim‐
h re
hole
Specification not reached ing:
spec
es, in part or in w
P0014 16398 Bank1, exhaust camshaft timing advance
t to the co
Specification not reached
P0015 16399 Bank1, exhaust camshaft timing retard ⇒ Rep. Gr. 15; Repairing valve
Specification not reached gear; checking variable valve
rrectness of i
timing
l purpos
– Checking variable valve tim‐

ing solenoid valve:
⇒ page 29 , final control di‐
nform
ercia
agnosis
m
a
com
t
– Checking valve timing
ion in
r
P0101 16485 Air mass meter -G70- implausible signal – Check air mass meter
te o
thi
⇒ page 96
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
SAE V.A.G
co Vo
by lksw
cted agen
Prote
P0102 16486 Air mass meter -G70- signal too low – Check air mass meter
AG.
⇒ page 96
P0103 16487 Air mass meter -G70- signal too high – Check intake system for
leaks (unmetered air)
⇒ page 124
– Check fuse 34
P0112 16496 Intake air temperature sender -G42- signal too low – Check intake air temperature
sender ⇒ page 108
P0113 16497 Intake air temperature sender -G42- signal too high
P0116 16500 Coolant temperature sender -G62- implausible signal – Check coolant temperature
sender ⇒ page 104
P0117 16501 Coolant temperature sender -G62- signal too low – Check thermostat: ⇒ Rep.
Gr. 19; Removing and instal‐
ling parts of cooling system;
Parts of cooling system, en‐
gine-side
P0118 16502 Coolant temperature sender -G62- signal too low

SAE V.A.G
P0130 16514 Bank 1, probe 1 electrical fault in circuit Checking– Lambda probe
ageing bank 1 Lambda
probe 1 ⇒ page 134
2. Fault memory 11
. Volkswage
Passat 1997 ➤ wage
n AG n AG d
oes
olks not
Motronic injection and ignitiondsystem
by
V (5-cyl. 4-valve) - Edition 11.2009
gu
ar
e an
ris tee
tho or
Fault code ss
Fault text au acFault
remedy
ce
P0133 16517 Bank 1 probe 1 signal too slow – Checking Lambda probe and
e
nl
pt
du
Lambda control after catalyt‐
an
itte
y li
ic converter ⇒ page 131
erm
ab
ility
P0134 16518 Bank 1 probe 1 no activity – Checking Lambda probe and
ot p
wit
Lambda control before cata‐
, is n
h re
lytic converter ⇒ page 128
hole
spec
P0135 16519 Bank 1 probe 1 electrical fault in heater circuit
es, in part or in w
t to the co
P0136 16520 Bank 1, probe 2 electrical fault in circuit – Checking Lambda probe and
rrectness of i
– Checking Lambda probe
heating after catalytic con‐
l purpos
verter ⇒ page 93
nform
mercia
at
om
ion
c
in t
r
SAE V.A.G
o
his
ate
do
riv
P0137 16521 Bank 1 probe 2 voltage too low – Checking Lambda probe and
p
cum
for
en
g

n
t.
yi Co
op
py
P0138 16522 Bank 1 probe 2 voltage too high . C rig
ht
rig ht
py by
o Vo
verter ⇒ page 93
by c lksw
cted agen
Prote AG.
P0139 16523 Bank 1 probe 2 signal too slow
P0140 16524 Bank 1 probe 2 no activity
P0141 16525 Bank 1 probe 2 electrical fault in heater circuit

SAE V.A.G
P0170 16554 Bank 1, fuel measurement system malfunction – Checking fuel pressure reg‐
ulator and holding pressure
⇒ page 119 .
– Checking injectors
⇒ page 116 , checking quan‐
tity injected and checking for
leaks
– Check fuel pump: ⇒ Rep. Gr.
20; Removing and installing
parts of fuel supply system;
Checking fuel pump
– Check secondary air system
for leaks: ⇒ Rep. Gr. 26;
Secondary air system
– Checking hoses and con‐
necting pipes to and be‐
tween components: ⇒ Rep.
Gr. 26; Secondary air system
– Check vacuum lines for
leaks

SAE V.A.G

Passat 1997 ➤

AG. Volkswagen AG d
agen
P0171 16555 Bank 1, fuel measuring system, system Votoo
lksw lean – Checking
oes
not fuel pressure reg‐
g
d by ulator anduaholding
ran pressure
ise
thor ⇒ page 119 . tee
or
au a
ss – Checking injectorsc
ce
e
nl
pt
du
an
itte
y li
leaks
erm
ab
ility
– Checking fuel pump:
ot p
wit
, is n
h re
– Checking suction-jet pump:
hole ⇒ Rep. Gr. 20; Removing
spec
and installing parts of fuel
es, in part or in w
t to the co
supply system
– Check intake system for
leaks ⇒ page 124
rrectness of i
– Checking exhaust system for
l purpos
leaks: ⇒ Rep. Gr. 26; Re‐

moving and installing parts of
exhaust system
nf
ercia
or
m
m
atio
om
n in
or c
thi
e

t
sd
iva
o
leaks
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
SAE V.A.G
cted agen
Prote AG.
P0172 16556 Bank 1, fuel measuring system, system too rich – Checking fuel pressure reg‐
⇒ page 119 .
leaks
– Checking activated charcoal
filter solenoid valve 1: ⇒
Rep. Gr. 20; Activated char‐
coal filter system; Checking
activated charcoal filter sole‐
noid valve 1

SAE V.A.G
P0201 16585 Injector, cylinder 1 -N30- electrical fault in current circuit – Checking injectors
⇒ page 113 .
P0202 16586 Injector, cylinder 2 -N31- electrical fault in current circuit
P0219 16603 Maximum engine speed exceeded – Erase fault memory
⇒ page 8
P0221 16605 Throttle valve drive angle sender 2 for electric throttle -
G188- implausible signal
G188- signal too low
2. Fault memory 13
Passat 1997 ➤

P0223 16607 Throttle valve drive angle sender 2 for electric throttle - Checking throttle valve control
G188- signal too high module ⇒ page 99
P0226 16610 Accelerator position senders 1/2 -G79+ -G185- implausi‐ – Checking accelerator posi‐
ble signal n AG. tion
Volkssender:
wagen AG⇒ Rep. Gr. 20;
lkswage Electronic engine
does output
not
o
d byV control (electronic throttle
gu
ara
horis
e
control); Checking accelera‐
nte
eo
aut tor position sender ra
c
ss
P0227 16611 Accelerator position sender -G79- signal too low
ce
e
nl
pt
du
P0228 16612 Accelerator position sender -G79- signal too high
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
SAE V.A.G
es, in part or in w
t to the co
P0261 16645 Injector, cylinder 1 -N30- short-circuit to earth – Checking injectors
⇒ page 113 .
P0262 16646 Injector, cylinder 1 -N30- short-circuit to positive
rrectness of i
P0264 16648 Injector, cylinder 2 -N31- short-circuit to earth
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
riv

p
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
SAE V.A.G
P0300 16684 Misfiring recognised – Checking injectors
⇒ page 113 .
P0301 16685 Cyl. 1 misfiring recognised – Checking ignition cables and
spark plugs ⇒ page 154
P0302 16686 Cyl. 2 misfiring recognised – Checking ignition transform‐
er ⇒ page 160
P0303 16687 Cyl. 3 misfiring recognised – Checking misfiring detection
⇒ page 166
P0304 16688 Cyl. 4 misfiring recognised
P0305 16689 Cyl. 5 misfiring recognised
P0321 16705 Engine speed sender -G28- implausible signal – Checking engine speed
sender ⇒ page 112
P0322 16706 Engine speed sender -G28- no signal
P0327 16711 Knock sensor 1 -G61- signal too low – Checking knock sensors
⇒ page 163
P0328 16712 Knock sensor 1 -G61- signal too high – Loosen knock sensor and
tighten again to 20 Nm
P0332 16716 Knock sensor 2 -G66- signal too low
P0333 16717 Knock sensor 2 -G66- signal too high

SAE V.A.G

Passat 1997 ➤

P0341 16725 Camshaft position sensor sender -G40- implausible signal – Checking Hall sender
⇒ page 158
P0342 16726 Camshaft position sensor sender -G40- signal too low
P0343 16727 Camshaft position sensor sender -G40- signal too high
P0346 16730 Camshaft position sensor sender -G163- implausible sig‐
nal
P0347 16731 Camshaft position sensor sender -G163-
short-circuit to earth
P0348 16732 Camshaft position sensor sender -G163- short-circuit to
positive

SAE V.A.G
P0411 16795 Secondary air system flow incorrect – Checking secondary air
AG. Volkswagen Apump
G do motor: ⇒ Rep. Gr. 26;
agen es n
ksw
by Vol
Secondary
ot g air system
ua
ed ran
horis
– Checking combination
tee valve:
aut ⇒ Rep. Gr. 26; Secondary
or
a air
ss c
system
ce
le
un
pt
– Checking secondary air in‐
an
d
itte
jection valve: ⇒ Rep. Gr. 26;
y li
erm
ab
ility
ot p
wit
is n
h re
necting pipes to and be‐
ole,
tween components: ⇒ Rep.
spec
Gr. 26; Secondary air system
t to the co
rrectne
SAE V.A.G
ss
P0420 16804 Bank1, catalytic converter system effect too low – Checking Lambda probe and
o
cial p
f i
nform
mer
atio
m
– Checking Lambda probe and

o
n
c
i
or

thi
te

sd
iva
o
pr
cum
r
fo

en
ng
t.
yi
ageing bank 1 Lambda
Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
If fault is only detected alone, i.e. without Lambda probe or reg‐

ulation faults, catalytic converter must be checked for damage
and renewed if necessary.

SAE V.A.G
P0440 16824 Tank vent system malfunction – Checking activated charcoal
filter solenoid valve 1
agnosis
2. Fault memory 15
Passat 1997 ➤

. VolkswaRep. Gr.
doe20; Activated char‐
en AG gen AG
ag
Volksw coal filter ssystem;
not
gu
Checking
edb
y
activated charcoal
ara filter sole‐
nte
ris noid valve 1
ho eo
aut ra
ss – Checking hoses and con‐ c
necting pipes from fuel tank
ce
le
un
pt
to throttle valve module: ⇒
an
d
itte
y li
erm
ab
ility
ot p activated charcoal filter sys‐
wit
is n
tem for leaks
h re
ole,
spec
t to the co
SAE V.A.G
rrectne
P0441 16825 Tank vent system flow incorrect – Checking activated charcoal
ss
o
cial p
f
inform
mer
noid valve 1
atio
m

o
n
c
i
or
n
necting pipes from fuel tank
thi
te
to throttle valve module: ⇒
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi
activated charcoal filter sys‐
Co
op py
tem for leaks
. C rig
ht ht
rig by
py
P0501 16885 Vehicle speed signal implausible – Checking speed signal
co Vo
by lksw
cted
⇒ page 146
agen
Prote AG.
P0506 16890 Idling speed regulation, speed below specification – Checking throttle valve con‐
trol module ⇒ page 99
P0507 16891 Idling speed regulation, speed above specification – Checking throttle valve con‐
– Checking alternator
– Checking battery: ⇒ Electri‐

cal system; Rep. Gr. 27;
Checking and charging bat‐
tery

SAE V.A.G
P0560 16944 Voltage supply signal implausible – Checking voltage supply
⇒ page 138 .
P0562 16946 Voltage supply too low – Procedure after interrupting
the voltage supply
⇒ page 139
P0563 16947 Voltage supply too high
P0568 16952 CCS switch -E45- implausible signal – Checking cruise control sys‐
tem: ⇒ Rep. Gr. 27; Electri‐
cal system
– Evaluate measured value
block 66

AG. Volkswagen AG d
agen oes
o lksw not
yV gu
ed b ara
nt
Passat 1997 ➤
ris
Motronic
ut
ho injection and ignition system (5-cyl. e4-valve)
eo
ra
- Edition 11.2009
s a c
s
ce
e
nl
pt
du
an
itte
P0571 16955 Brake light switch -F implausible signal
6)
– Checking signal from brake
y li
erm
ab
light switch and brake pedal
ility
ot p
switch ⇒ page 149
wit
, is n
h re
hole
spec
es, in part or in w
6) The system monitors both brake light switch -F and brake pedal switch -F47- .
t to the co
SAE V.A.G
rrectness of i
P0600 16984 Drivetrain data bus message missing – Check data bus
l purpos
⇒ page 152
– Checking control unit in dash
nform
ercia
panel insert: ⇒ Electrical

system self-diagnosis; Rep.
m
at
Gr. 01; Checking diagnostic
om
ion
interface for data bus
c
in t
or
his
e
P0601 16985 Control unit defective – Renewing engine control unit

at
do
riv
-J220- ⇒ page 140

p
cum
or
P0604 16988 Control unit defective

f
en
ng
t.
yi Co
op
P0605 16989 Control unit defective C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.3 Fault table: from V.A.G code 17455 /
SAE P1 or P3 codes
Note
♦ The fault code overview is listed according to SAE or V.A.G

code.
♦ After fault rectification, the fault memory must be erased
⇒ page 8 and the readiness code regenerated ⇒ page 44 .

SAE V.A.G
P1047 17455 Bank 1, exhaust camshaft control valve 1 -N318- – Checking exhaust camshaft
electrical fault in current circuit control valve 1 -N318- :
agnosis
P1048 17456 Bank 1, exhaust camshaft control valve 1 -N318-
short-circuit to positive
P1049 17457 Bank 1, exhaust camshaft control valve 1 -N318- ⇒ Rep. Gr. 15; Repairing valve
short-circuit to earth gear; checking variable valve
timing
P1050 17458 Bank 1, exhaust camshaft control valve 1 -N318- ⇒ Current flow diagrams, Elec‐
open circuit trical fault finding and Fitting lo‐
cations

SAE V.A.G
P1102 17510 Bank 1, probe 1 heating current circuit short-circuit to pos‐ – Checking Lambda probe
itive heating before catalytic con‐
verter ⇒ page 91
2. Fault memory 17
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
Passat 1997 ➤ ir se
d ran
te
o
auth system (5-cyl. 4-valve) - Edition 11.2009 e or a
ss c
ce
le
un
pt
an
d
itte
y li
P1105 17513 Bank 1 probe 2 heating current circuit short-circuit to pos‐ – Checking Lambda probe
rm
ab
itive heating after catalytic con‐
pe
ility
verter ⇒ page 93
ot
wit
, is n
h re
P1111 17519 Lambda control (bank 1), system too lean hole – Checking Lambda probe and
spec
es, in part or in w
t to the co
P1112 17520 Lambda control (bank 1), system too rich
P1115 17523 Bank 1, probe 1 heating current circuit short-circuit to – Checking Lambda probe
rrectness of i
earth heating before catalytic con‐
verter ⇒ page 91
l purpos
P1116 17524 Bank 1, probe 1 heating current circuit open circuit
nform
mercia
a
com
t
ion in
r
SAE V.A.G
te o
thi
s
iva
P1117 17525 Bank 1, probe 2 heating current circuit short-circuit to – Checking Lambda probe
do
r
rp
c
earth heating after catalytic con‐
um
fo
en
g
verter ⇒ page 93
n
t.
yi Co
op
P1118 17526 Bank 1, probe 2 heating current circuit open circuit
C py
t. rig
gh ht
yri by
P1127 17535 Bank 1, mixture adaptation (mult.) System too rich – Checking fuel pressure reg‐
cop Vo
by lksw
cted ulator and holding pressure
agen
Prote AG.
⇒ page 119 .
leaks
noid valve 1

SAE V.A.G
P1128 17536 Bank 1, mixture adaptation (mult.) System too lean – Checking fuel pressure reg‐
⇒ page 119 .
leaks
– Checking fuel pump: ⇒ Rep.
Gr. 20; Checking fuel pump
leaks ⇒ page 124
exhaust system
leaks

Passat 1997 ➤

SAE V.A.G
P1136 17544 Bank 1, mixture adaptation (add.) system too lean – Checking fuel pressure reg‐
⇒ page 119 .
leaks
– Check fuel pump: ⇒ Rep. Gr.
20; Removing and installing
agen
AG. Volkswagen AG d
oes
parts of fuel supply system;
Volksw not
gu
Checking fuel pump
by ara
rise
d
nte – Check intake system for
autho eo
ra leaks ⇒ page 124
s c
s – Checking exhaust system for
ce
e
nl
pt
du
an
itte
y li
exhaust system
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
leaks
rrectness of i
l purpos
Note
nf
ercia
add. = additive means that the fault only has an effect at idling
orm
speed.
m
atio
om
n in
or c

thi
te
sd
iva
SAE V.A.G
o
r
rp
cu
o
P1137 17545 Bank 1, mixture adaptation (add.) system too rich – Checking fuel pressure reg‐
f
en
ng
t.
yi
Co
op py
⇒ page 119 .
t. C rig
gh ht
yri by
cop Vo
by lksw
cted
agen
Prote AG.
leaks
noid valve 1
Note
add. = additive means that the fault only has an effect at idling
speed.

SAE V.A.G
2. Fault memory 19
Passat 1997 ➤

P1142 17550 Load detection limit not reached – Checking throttle valve con‐
P1143 17551 Load detection limit exceeded – Check air mass meter
⇒ page 96
– Checking accelerator posi‐

tion sender: ⇒ Rep. Gr. 20;
Electronic engine output
control (electronic throttle
tor position sender

SAE V.A.G
P1151 17559 Bank 1, mixture adaptation range 1 lean limit not reached – Checking fuel pressure reg‐
⇒ page 119 .
leaks
leaks ⇒ page 124
–G dChecking exhaust system for
AG. Volkswagen A
agen
Volksw leaks:
oes
not ⇒ Rep. Gr. 26; Re‐
d by moving gu
and
ara installing parts of
rise exhaust system
nte
tho eo
u ra
ss a
– Check secondary c air system
ce
le
un
pt

an
d
itte
y li

erm
ab
leaks
ility
ot p
wit
is n
h re
ole,
spec

t to the co
SAE V.A.G
P1152 17560 Bank 1, mixture adaptation range 2 lean limit not reached – Checking injectors
rrectne

leaks
ss o
cial p

f in

form
mer

atio
m
leaks ⇒ page 124

o
n
c
i
or
n thi

te
sd
a

iv
o
pr

um
r
fo
en
ng
exhaust system
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
leaks

Passat 1997 ➤

SAE V.A.G
P1165 17573 Bank 1, mixture adaptation range 1 rich limit exceeded – Checking fuel pressure reg‐
⇒ page 119 .
leaks
n AG. Volkswagen AG Rep. Gr. 20; Activated char‐
lkswage does
not g
Vo activated charcoal filter sole‐
d by ua
r
ris
e ante noid valve 1
tho eo
au adaptation range 2 rich limit exceeded
P1166 17574 Bank 1, mixture – Checking
ra
c fuel pressure reg‐
ss
ce
le
un
⇒ page 119 .
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
leaks
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
noid valve 1
l purpos
nform
ercia

SAE V.A.G
m
a
com
tion in
P1171 17579 Throttle valve drive angle sender 2 for electric throttle - – Checking throttle valve con‐
r
te o
G188- implausible signal trol module ⇒ page 99

thi
s
iva
do
r
rp
cum
G188- signal too low

fo
en
ng
t.
yi
Co
Cop py
G188- signal too high
t. rig
gh ht
pyri by
P1176 17584 Bank 1 Lambda correction after catalytic converter control – Checking Lambda probe
co Vo
by lksw
cted
limit reached ageing bank 1 Lambda
agen
Prote AG.
leaks ⇒ page 124

SAE V.A.G
P1187 17595 Linear Lambda probe / compensation resistance – Checking Lambda probe and
open circuit Lambda control before cata‐

2. Fault memory 21
Passat 1997 ➤

P1191 17599 Linear Lambda probes before catalytic converter inter‐ – Checking Lambda probes for
changed interchange ⇒ measured val‐
ue block 39
P1196 17604 Bank 1, probe 1 heater circuit electrical fault – Checking Lambda probe
heating before catalytic con‐
verter ⇒ page 91
P1198 17606 Bank 1, probe 2 heater circuit electrical fault – Checking Lambda probe
verter ⇒ page 93

SAE V.A.G
P1213 17621 Injector, cylinder 1 -N30- short-circuit to positive – Checking injectors
⇒ page 113 .
AG. Volkswagen AG d
P1227 17635 Injector, cylinder 3 -N32- short-circuit lkswto earth
agen oes
not
o
yV gu
P1228 17636 Injector, cylinder 4 -N33- short-circuit
ised b to earth ara
nte
or eo
P1229 17637 Injector, cylinder 5 -N83-aushort-circuit
th to earth ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
SAE V.A.G ility

ot
wit
, is n
P1237 17645 Injector, cylinder 1 -N30- open circuit – Checking injectors h re

hole
⇒ page 113 .
spec
es, in part or in w
P1238 17646 Injector, cylinder 2 -N31- open circuit

t to the co

rrectness of i

l purpos
P1250 17658 Fuel level too low Fuel level less than 5 litres, fuel
vehicle
nform
ercia
Checking signal from fuel tank

level sender: ⇒ Electrical sys‐
m
a
com
tem; Rep. Gr. 01; Dash panel

ion in
insert self-diagnosis; Reading

r
te o
thi
measurement value block

s
iva
do
P1255 17663 Coolant temperature sender -G62- short-circuit to earth – Check coolant temperature
r
rp
cum
fo
sender ⇒ page 104

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Fault “fuel level too low” is also detected in connection with mis‐
firing. This fault is not therefore sporadic, i.e. a subsequent fault
in Lambda control or misfiring is also detected.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or e
h
aut Passat 1997or a➤ c
s
Motronic injection and ignition system (5-cyl. 4-valve) - Edition 11.2009 s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
SAE V.A.G
ot p
wit
, is n
P1296 17704 Fault in cooling system – Check coolant temperature
h re
sender ⇒ page 104
hole
spec
es, in part or in w
– Checking thermostat: ⇒
t to the co
Rep. Gr. 19; Removing and
installing parts of cooling
system; Parts of cooling sys‐
rrectness of i
tem, engine-side
l purpos
P1325 17733 Cylinder 1 knock control, control limit reached – Checking knock sensor and
knock control ⇒ page 163
nf
ercia
P1326 17734 Cylinder 2 knock control, control limit reached – Eradicate abnormal noises
or
with engine running (ancilla‐
m
m
atio
ries loose, brackets/bolts
om
n in
broken)
or c
thi
e
P1327 17735 Cylinder 3 knock control, control limit reached – Checking connectors and
t
sd
iva
lines according to current
o
r
rp
cu
flow diagram: ⇒ Current flow
o
m
f
en
ng
diagrams, Electrical fault

t.
yi Co
op
finding and Fitting locations
C py
t. rig
gh ht
– Loosen knock sensor and
yri
P1328 17736 Cylinder 4 knock control, control limit reached p by
o Vo
by c
tighten again to 20 Nm
lksw
cted agen
Prote AG.
– Change type of fuel
P1329 17737 Cylinder 5 knock control, control limit reached

SAE V.A.G
P1335 17743 Engine torque monitor 2 control limit exceeded
P1336 17744 Engine torque monitor control limit exceeded – Check air mass meter
⇒ page 96
– Check intake air temperature
sender ⇒ page 108
– Check coolant temperature
sender ⇒ page 104
P1337 17745 Bank 1, camshaft position sensor -G40- short-circuit to Checking Hall sender
earth ⇒ page 158
P1338 17746 Bank 1, camshaft position sensor -G40- open circuit /
P1340 17748 Camshaft/crankshaft position sensor wrong allocation – Checking Hall sender
⇒ page 158
P1347 17755 Bank 2, camshaft/crankshaft position sensor wrong allo‐ – Checking engine speed
cation sender ⇒ page 112

SAE V.A.G
P1355 17763 Ignition actuation, cylinder 1 open circuit – Checking ignition coils with
output stages ⇒ page 160
P1356 17764 Ignition actuation, cylinder 1 short-circuit to positive
P1357 17765 Ignition actuation, cylinder 1 short-circuit to earth
P1358 17766 Ignition actuation, cylinder 2 open circuit
2. Fault memory 23
Passat 1997 ➤


SAE V.A.G
-J220- ⇒ page 140
P1391 17799 Bank 2, camshaft position sensor sender -G163- – Checking Hall sender
short-circuitsw toagearth
en AG. V
olkswagen AG
does ⇒ page 158
olk not
P1392 17800 Banked2,b camshaft position sensor sendergu-G163-
y V
ara
open
ho
ris circuit/short-circuit to positive nte
e t or
au ac
ss
ce
e
nl
pt
du
an

itte
y li
erm
ab
SAE V.A.G
ility
ot p
P1410 17818 Tank vent valve -N80- short-circuit to positive – Checking activated charcoal
wit
, is n
h re

hole

spec
agnosis
es, in part or in w
t to the co
P1421 17829 Secondary air inlet valve -N112- short-circuit to earth – Checking secondary air inlet
valve ⇒ page 29 , final con‐
trol diagnosis
rrectness of i
P1422 17830 Secondary air inlet valve -N112- short-circuit to positive

l purpos
P1424 17832 Bank 1, secondary air system leak detected – Check secondary air system
nf
ercia

orm
P1425 17833 Tank vent valve -N80- short-circuit to earth – Checking activated charcoal
m
atio
m

o
n in
c

or
thi
e
agnosis
t
sd
iva
o
r
rp
cu
P1426 17834 Tank vent valve -N80- open circuit

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
SAE V.A.G Prote AG.
P1427 17835 Actuation, vacuum pump for brakes

P1428 17836 Actuation, vacuum pump for brakes – Checking actuation, vacuum
short-circuit to earth pump for brakes -V192- :
agnosis
P1429 17837 Actuation, vacuum pump for brakes open circuit – Carrying out short test, ac‐
tuation, vacuum pump for
brakes: ⇒ Brake systems,
Rep. Gr. 47

Passat 1997 ➤

P1430 17838 Actuation, vacuum pump for brakes – Checking actuation of brake
open circuit / short-circuit to positive servo relay -J569- :
P1431 17839 Actuation, vacuum pump for brakes ⇒ Current flow diagrams, Elec‐
open circuit / short-circuit to earth trical fault finding and Fitting lo‐
cations

SAE V.A.G
P1432 17840 Secondary air inlet valve -N112- open circuit Checking secondary
– air inlet
valve ⇒ page 29 , final con‐
trol diagnosis
P1433 17841 Secondary air pump relay -J299- open circuit – Checking secondary air
pump relay ⇒ page 29 , fi‐
nal control diagnosis
P1434 17842 Secondary air pump relay -J299- short-circuit to positive
P1435 17843 Secondary air pump relay -J299- short-circuit to earth
P1479 17887 Brake vacuum system mechanical fault – Checking pump motor: ⇒
Brake systems, Rep. Gr. 47;
P1500 17908 Fuel pump relay -J17- electrical fault in current circuit
P1501 17909 Fuel pump relay -J17- short-circuit to earth – Checking fuel pump relay:
⇒ Current flow diagrams,
Electrical fault finding and
Fitting locations
P1502 17910 Fuel pump relay -J17- short-circuit to positive olksw AG. V agen AG
agen does
olksw not
yV gu
db ara
rise nte
o
Fault code Fault textauth Fault remedye or a
s c
SAE V.A.G s
ce
le
un
pt
P1512 17920 Variable intake manifold changeover valve -N156- short-
an
d
itte
y li
circuit to positive
erm
ab
ility
P1515 17923 Variable intake manifold changeover valve -N156- short- – Checking variable intake
ot p
circuit to earth manifold changeover valve
wit
is n
h re
ole,
agnosis
spec
P1516 17924 Variable intake manifold changeover valve -N156- open

circuit t to the co
P1519 17927 Bank 1, variable valve timing malfunction ⇒ Rep. Gr. 15; Repairing valve
rrectne
gear; checking variable valve

timing
s
P1523 17931 Crash signal from airbag CU implausible signal – Check whether control unit is
s o
CAN bus, capable, renew if

cial p
f in
necessary
form
mer
P1526 17934 Bank 1, camshaft control valve -N205- – Checking exhaust camshaft
atio
m
short-circuit to positive control valve 1 -N205- :

o
n
c

or
n thi
e
agnosis
t
sd
iva
o
pr
⇒ Rep. Gr. 15; Repairing valve

c
P1527 17935 Bank 1, camshaft control valve -N205-

um
r
fo
short-circuit to earth gear; checking variable valve

en
ng
t.
yi
timing
Co
Cop py
ht. rig
P1528 17936 Bank 1, camshaft control valve 1 -N205- open circuit ⇒ Current flow diagrams, Elec‐ rig ht
py by
trical fault finding and Fitting lo‐ co Vo
by lksw
cted
cations
agen
Prote AG.
2. Fault memory 25
Passat 1997 ➤

SAE V.A.G
P1539 17947 Clutch pedal switch -F36- implausible signal – Checking clutch pedal switch
⇒ page 149
P1541 17949 Fuel pump relay -J17- open circuit – Checking fuel pump relay:
⇒ Current flow diagrams,
Electrical fault finding and
Fitting locations
P1542 17950 Throttle valve drive angle sender 1 for electric throttle - – Checking throttle valve con‐
G187- implausible signal agen
AG. Volkswagen Atrol
G do module ⇒ page 99
es n
olksw ot g
P1543 17951 Throttle valve drive angle sender 1dfor by electric throttle -
V ua
ran
G187- signal too low oris
e
tee
th or
u
P1544 17952 Throttle valve drive angle sender
ss
a 1 for electric throttle - ac
G187- signal too high
ce
le
un
pt
P1545 17953 Throttle valve control malfunction
an
d
itte
y li
rm
P1558 17966 Throttle valve drive for electric throttle -G186- electrical
ab
pe
ility
fault in current circuit
ot
wit
, is n
P1559 17967 Throttle valve module -J338- fault in basic setting – Adapting engine control unit
h re
hole
to throttle valve module
spec
⇒ page 143
es, in part or in w
t to the co
rrectness of i
SAE V.A.G
l purpos
P1564 17972 Throttle valve module -J338-

low voltage at basic setting
nform
ercia
P1565 17973 Throttle valve module -J338- lower stop not reached – Checking throttle valve con‐
m
a
com
tion in
P1568 17976 Throttle valve module -J338- mechanical fault
r
te o
thi
s
P1569 17977 CCS switch -E45- implausible signal – Checking cruise control sys‐
iva
do
r
tem: ⇒ Rep. Gr. 27; Electri‐

rp
cum
fo
cal system
en
ng
t.
yi Co
– Evaluate measured value
Cop py
. rig
block 66
ht ht
rig by
opy Vo
P1570 17978 Engine control unit locked – Adapting engine control unit
by c lksw
cted agen
to electronic immobiliser: ⇒
Prote AG.
Electrical system self-diag‐

nosis; Rep. Gr. 01; Immobil‐
iser self-diagnosis; Adapta‐
tion on renewing engine
control unit
Note on fault code 17978:

♦ If starting is attempted with an unauthorised key a permanent
fault will be stored. After a subsequent start with an authorised
key the fault will be converted to a sporadic fault.
SAE V.A.G
P1579 17987 Throttle valve module -J338- – Adapting engine control unit
adaptation not started to throttle valve module
⇒ page 143
P1602 18010 Voltage supply terminal 30 voltage too low – Checking control unit voltage
supply ⇒ page 138
-J220- ⇒ page 140

Passat 1997 ➤

P1609 18017 Crash shut-off triggered – Erase fault memory
⇒ page 8 ⇒ Body self-diag‐
nosis; Rep. Gr. 01; Self-di‐
agnosis; Self-diagnosis for
airbag systems
-J220- ⇒ page 140
P1612 18020 Engine control unit incorrectly coded – Coding engine control unit
⇒ page 141
P1624 18032 Warning lamp on request active – Read fault memories of all
control units ⇒ page 9
P1626 18034 Powertrain data bus no messages from gearbox control – Checking matching resistor
unit for data bus ⇒ page 152

SAE V.A.G
P1630 18038 Accelerator position sender -G79- signal too low – Checking accelerator posi‐
tion sender:
P1631 18039 Accelerator position sender -G79- signal too high ⇒ Rep. Gr. 20; Electronic en‐
gine output control (electronic
throttle control); Checking ac‐
celerator position sender
n AG. Volkswagen AG
P1633 18041 Accelerator position sender 2 -G185- ksw signal too low
age does
not
y Vol gu
P1634 18042 Accelerator position senderise2d b-G185- signal too high ara
nte
or eo
P1636 18044 Drivetrain data bus message
aut
h
from ABS control unit miss‐ – Check data r a bus
ing ss ⇒ page 152c
ce
le
un
P1639 18047 Accelerator position senders 1/2 -G79+G185 – Checking accelerator posi‐
pt
an
d
itte
implausible signal tion sender: ⇒ Rep. Gr. 20;
y li
erm
ab
Electronic engine output
ility
ot p
control (electronic throttle
wit
is n
h re
tor position sender
ole,
spec
P1640 18048 Control unit defective – Renewing engine control t to the co

unit -J220- ⇒ page 140 rrectne

s
SAE V.A.G
s o
cial p
P1648 18056 Powertrain data bus defective – Checking matching resistor

inform
for data bus ⇒ page 152

mer
atio
P1649 18057 Powertrain data bus message from ABS control unit miss‐
om
ing
n
c
i
or
n thi
e
– Reading ABS control unit

t
sd
va
fault memory: ⇒ Running

i
o
pr
cum
r
gear self-diagnosis for ABS;

fo
en
ng
Rep. Gr. 01; Performing self-

t.
yi Co
op
diagnosis; Reading fault
C py
t. rig
memory
gh ht
pyri by
Vo
o
by c
P1650 18058 Drivetrain data bus message from instrument cluster – Checking matching resistor
lksw
cted agen
Prote
missing for data bus ⇒ page 152
AG.
– Checking dash panel insert:

⇒ Electrical system self-di‐
agnosis; Rep. Gr. 01; Dash
panel insert self-diagnosis
05.99 ▸; Performing self-di‐
agnosis
2. Fault memory 27
Passat 1997 ➤

SAE V.A.G
P1677 18085 Electronic power control fault lamp -K132- – Checking matching resistor
short-circuit to positive for data bus ⇒ page 152
P1678 18086 Electronic power control fault lamp -K132- – Checking dash panel insert:
short-circuit to earth ⇒ Electrical system self-di‐
panel insert self-diagnosis
agnosis
P1679 18087 Electronic power control fault lamp -K132- n AG. Volkswagen AG
open circuit ksw
age does
not
y Vol gu
P1682 18090 Drivetrain data bus implausibleisemessage from ABS con‐ – Checking
d b ara matching resistor
nte
trol unit uthor
for data bus e⇒
or page 152 ⇒
ss a Electrical systemac self-diag‐
nosis; Rep. Gr. 01;
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
SAE V.A.G
h re
hole
spec
P1683 18091 Drivetrain data bus implausible message from ABS con‐ – Checking matching resistor
es, in part or in w
trol unit for data bus ⇒ page 152
t to the co
– Checking airbag system: ⇒
Body self-diagnosis; Rep.
Gr. 01; Self-diagnosis for air‐
rrectness of i
bag systems
l purpos
P1691 18099 Fault lamp for self-diagnosis -K83- open circuit – Checking matching resistor
for data bus ⇒ page 152
nform
ercia
P1692 18100 Fault lamp for self-diagnosis -K83- – Checking dash panel insert:
short-circuit to earth ⇒ Electrical system self-di‐
m
at
om

ion
c
panel insert self-diagnosis in t

or
his
e

at
do
riv
agnosis
p
cum
or
P1693 18101 Fault lamp for self-diagnosis -K83-

f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
SAE V.A.G
P1912 18320 Brake servo pressure sensor -G294- – Checking connector:
short-circuit to positive / open circuit
P1913 18321 Brake servo pressure sensor -G294- – Checking signal from pres‐
short-circuit to earth sure sensor: ⇒ Brake sys‐
tems, Rep. Gr. 47;
P1914 18322 Brake servo pressure sensor -G294- ⇒ Current flow diagrams, Elec‐
implausible signal trical fault finding and Fitting lo‐
cations

Passat 1997 ➤
3 Final control diagnosis
3.1 Performing final control diagnosis

The final control diagnosis activates the following components in
the stated sequence:
1. Activated charcoal filter solenoid valve 1 -N80-
2. Secondary air inlet valve -N112-
3. Secondary air pump relay -J299-
4. Variable intake manifold changeover valve -N156-
5. Camshaft control valve 1 -N205-
6. Camshaft control valve 1 -N318-
7. Vacuum pump for brakes -V192- (with automatic gearbox
only)
8. Injector, cylinder 1 -N30-
9. Injector, cylinder 2 -N31- AG. Volkswagen AG d
agen oes
olksw not
10. Injector, cylinder 4 -N33- d by V gu
ara
ise nte
11. Injector, cylinder 5 -N83- uthor eo
a ra
12. Injector, cylinder 3 -N32- ss c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Final control diagnosis can only be carried out if the engine is
, is n
h re
stationary and ignition switched on.
hole
spec
♦ Final control diagnosis will be aborted if the engine is started
es, in part or in w
t to the co
or a rotational impulse is recognised.
♦ During final control diagnosis, the individual final controls will
be activated for approx. 60 s, unless the next final control is
rrectness of i
selected by pressing the → key.
l purpos
♦ Final control diagnosis can be aborted by pressing the C but‐

ton. It does not therefore have to be continued to the end with
nf
ercia
the → button. This is particularly important as the injectors are
orm
actuated according to the firing sequence with the → button
m
atio
m
and inject fuel.

o
n in
or c
thi
♦ The electric fuel pump runs continuously throughout the final

te
sd
a
control diagnosis.
iv
o
r
rp
cu
o
♦ The control elements can be tested either by listening or by

f
en
ng
t.
yi
touching.
Co
Cop py
t. rig
gh
♦ Final control diagnosis is aborted after 1 minute if no further
ht
pyri by
Vo
final control is actuated.
co lksw
by
cted agen
Prote AG.
♦ If you wish to repeat final control diagnosis, the engine must
be run briefly beforehand.

♦ Fault reader -V.A.G 1551- or vehicle system tester -
V.A.G 1552- with cable -V.A.G 1551/3-
♦ Test box -V.A.G 1598/31-
♦ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715-
♦ Diode test lamp -V.A.G 1527-
♦ Auxiliary measuring set -V.A.G 1594-
3. Final control diagnosis 29

Passat 1997 ➤
♦ Current flow diagram

AG. Volkswagen AG d
Test prerequisites lksw
agen oes
not
Vo gu
y
• All fuses must be OK. rise
d b ara
nte
tho eo
Procedure: s au ra
c
s
ce
e
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Then switch
nl
pt
du
ignition on and select engine control unit with “Address word”
an
itte
y li
01. (Connect fault reader and select engine control unit
erm
ab
⇒ page 4 )
ility
ot p
wit
, is n
h re
hole
spec
Rapid data transfer HELP
es, in part or in w
Select function XX
t to the co
display:
rrectness of i
– Press keys 0 and 3 for function “Final control diagnosis”.
l purpos
nf
ercia
o
Rapid data transfer Q
rm
03-Final control diagno-
m
atio
sis
om
n in
c
Activating activated charcoal filter solenoid valve 1 -N80- :

or
thi
te
sd
a
– Confirm entry with Q key.

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Final control diagnosis t. ->
rig
gh ht
Tank vent valve N80 pyri by
Vo
co lksw
by
cted agen
Activated charcoal filter solenoid valve 1 must click until the next Prote AG.
final control is activated by pressing the → button.
The valve clicks but a fault is still suspected (valve does not open
or close):
– Pull the hose off solenoid valve 1 and connect an auxiliary

hose to the valve's free connection.
– Blow into auxiliary hose during final control diagnosis (in di‐
rection of throttle valve control module). Valve must open and
close
If the solenoid valve does not click:
– Pull 2-pin connector from solenoid valve 1 -N80- -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise nte Passat 1997 ➤
h e
Motronic
aut injection and ignition system (5-cyl. 4-valve)or a-c Edition 11.2009
ss
ce
e
nl
– Connect the diode test lamp -V.A.G 1527- using adapter ca‐
pt
du
an
bles from -V.A.G 1594- to detached connector. The LED must
itte
y li
flash (bright/darker)
erm
ab
ility
ot p
LED flashes:
wit
, is n
h re
– Press the C button to end final control diagnosis.
hole
spec
Indicated on display: es, in part or in w
t to the co
Final control diagnosis aborted
rrectness of i
l purpos
– Renew solenoid valve ⇒ Rep. Gr. 20; Activated charcoal filter

system; Removing and installing parts of activated charcoal
filter system
nform
ercia
LED does not flash:

m
at
om
io
n
c
in t
or
his
te
a
do
priv
cum
for
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Connect test box -V.A.G 1598/31- to control unit wiring har‐ Prote
cted AG.
agen
ness. The engine control unit remains disconnected.
– Check line for open circuit between test box socket 64 and 2-
pin connector contact 2 using current flow diagram. Cable
resistance: max. 1.5 Ω.
– Additionally check wire for short circuit to battery positive and
earth.
– Check line between 2-pin connector contact 1 and fuel pump
relay -J17- for open circuit using current flow diagram. Cable
If no wiring fault is detected:
– Renew engine control unit ⇒ page 140 .
memory.
Activating secondary air inlet valve -N112- :
Final control diagnosis ->
Secondary air inlet valve N112
The secondary air inlet valve must click until the next control el‐
ement is activated by pressing the → button.
If valve does not click:

Passat 1997 ➤
– Pull 2-pin connector off secondary air inlet valve -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
– Connect the diodeaut test lamp -V.A.G 1527- using adapter ca‐
h
ra
bles from -V.A.G
s 1594- to detached connector. The LED must
s c
ce
le
un
pt
an
d
itte
LED flashes:
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Renewing secondary air inlet valve -N112- ⇒ Rep. Gr. 26;
rrectness of i
Secondary air system; Removing and installing parts of sec‐
ondary air system .
l purpos

nform

ercia
memory.
m
a
com
tio
LED does not flash:

n in
r
te o
thi

s
iva
do
r
rp
um
fo
en
ng
t.
yi Co
Final control diagnosis aborted Cop py
t. rig
gh ht
yri
– Switch off ignition. p by
o Vo
by c lksw
cted agen
Prote AG.
– Connect test box -V.A.G 1598/31- to control unit wiring har‐

Passat 1997 ➤
– Check line for open circuit between test box socket 44 and 2-
pin connector contact 2 using current flow diagram. Cable
earth. Specification: ∞ Ω.
Activating secondary air pump relay -J299- :
Secondary air pump relay J299
AG. Volkswagen AG d
agen oes
The secondary air pump relay -J299- activates the secondaryy air Vol
ksw not
gu
pump motor, and this runs at intervals until the next control e ele‐
d b ara
nte
ris
ment is activated by pressing the → button. tho eo
u ra
sa c
If the secondary air pump motor -V101- does not runs at intervals:
ce
le
un
pt
– Remove insulation tray: ⇒ General body repairs, exterior;
an
d
itte
y li
Rep. Gr. 50 ; Noise insulation .
erm
ab
ility
ot p
– Pull 2-pin connector off secondary air pump motor -arrow-.
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
flash
pr
cum
r
fo
en
ng
LED flashes:
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.

– Renew secondary air pump motor -V101- : ⇒ Rep. Gr. 26;
Secondary air system; Removing and installing parts of sec‐
ondary air system .
memory.
If LED does not flash, but the secondary air pump relay clicks:

Passat 1997 ➤
– Check line between secondary air pump motor -V101- contact

1 and body earth for open circuit. Cable resistance: max. 1.5
Ω.
– Pull secondary air pump relay -arrow- out of relay holder in

control unit protective housing.
Note
♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap.
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.
– Check line for open circuit between secondary air pump motor
contact 2 and contact 2 of relay plate. Cable resistance: max.
1.5 Ω.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Test voltage supply at contact 8 (terminal 30) for secondary

ility
ot p
air pump relay -J299- .

wit
, is n
h re
If the voltage supply is OK:

hole
spec
es, in part or in w
– Renew secondary air pump relay -J299- .

t to the co

rrectness of i
memory.
If the LED does not flash and the secondary air pump relay does
l purpos
not click:
nf
ercia

orm
m
atio
om
n in
or c

thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Pull secondary air pump relay -arrow- out of relay holder in

control unit protective housing.
Note
♦ If tools are necessary to pull relays or control units out of the

relay plate, first disconnect battery earth strap.
♦ Before disconnecting battery earth strap obtain code for radios
with anti-theft coding.
– Initiate final control diagnosis again and activate secondary air

pump relay -J299- .
– Connect diode test lamp -V.A.G 1527- using auxiliary cables

from -V.A.G 1594- to contacts 4 and 6 of relay plate. The LED
must flash
LED flashes:
AG. Volkswagen AG d
agen
– Press the C button to end final controlVodiagnosis.
lksw
oes
not
gu
y
db ara
Indicated on display: rise nte
tho eo
au ra
c
Final control diagnosis aborted ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Renew secondary air pump relay -J299- .
ility
ot p
wit
, is n
h re
hole
spec
memory.
es, in part or in w
t to the co
LED does not flash:
rrectness of i
l purpos

nform

mercia
at
om
– Connect diode test lamp -V.A.G 1527- using auxiliary cables

ion
c
from -V.A.G 1594- to contact 8 of relay plate and body earth.

in t
or
The LED should light up.

his
ate
do
priv
If LED does not light up:

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Check line between contact 8 of relay plate and fuel pump

relay -J17- for open circuit referring to current flow diagram.
Cable resistance: max. 1.5 Ω.
LED lights up:

– Check line for open circuit between test box socket 46 and
contact 4 of relay plate referring to current flow diagram. Cable
Activating intake manifold changeover valve -N156- :
Variable intake manifold changeover valve
N156
Variable intake manifold changeover valve must click until the

next final control is activated by pressing the → button.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
If sufficient vacuum is still present, variable intakeismanifold
ed
b ua
ran
changeover valve -N156- actuates actuator for thintake manifold
or tee
or
changeover. Valve is bolted on below the intake ss
au
manifold, on right ac
next to the secondary air inlet valve. Checking intake manifold
ce
le
change-over ⇒ page 122 .

un
pt
an
d
itte
y li
rm
ab
If valve does not click:

pe
ility
ot
wit
, is n
h re
– Pull 2-pin connector off variable intake manifold changeover

hole
valve -N156- -arrow-.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
LED flashes:
AG. Volkswagen AG d
agen oes
Indicated on display: olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
– Renew intake manifold changeover valve -N156- .
itte
y li
rm
ab
pe
ility
ot
wit
, is n
memory.
h re
hole
spec
LED does not flash:
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Check line for open circuit between test box socket 104 and
2-pin connector contact 2 using current flow diagram. Cable
Activate camshaft control valve 1 -N205- :
AG. Volkswagen AG d
agen oes
Final control diagnosis olksw -> not
Camshaft timing control byV gu
ara
ed
ris nte
ho eo
Inlet camshaft control valve aut
is actuated until the next final control ra
s c
is activated by pressing the → button.
s
ce
e
nl
pt
du
an
itte
y li
erm
Note
ab
ility
ot p
wit
, is n
In this final control diagnosis, only the valve -1- is actuated (barely
h re
audibly).
hole
spec
es, in part or in w
t to the co
If a malfunction is assumed:
– Pull 2-pin connector -1- off valve.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Connect the diode test lamp -V.A.G 1527- using adapter ca‐ py by
co Vo
by lksw
cted agen
Prote
flash
AG.
LED flashes:

– Checking variable valve timing: ⇒ Rep. Gr. 15; Repairing
valve gear; Checking variable valve timing .
LED does not flash:

Passat 1997 ➤

– Check line of valve -1- for open circuit between test box socket
114 and 2-pin connector contact 2 using current flow diagram.
olkswagen AG
– Additionally check wire for short circuit to battery spositive
wage
n AGand
.V
does
earth. Specification: ∞ Ω. by
Volk not
gu
d ara
ise nte
– Check line between 2-pin connector contactthor 1 and fuel pump eo
relay -J17- for open circuit using current
ss
au
flow diagram. Cable ra
c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
memory.
es, in part or in w
t to the co
Activate camshaft control valve 1 -N318- :
rrectness of i
l purpos

Camshaft timing control
nform
ercia
Exhaust camshaft control valve is actuated until the next final

m
control is activated by pressing the → button.

a
com
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
In this final control diagnosis, only the valve -2- is actuated (barely
n
t.
yi Co
audibly). Cop py
t. rig
gh ht
pyri by
Vo
o
If a malfunction is assumed:
c by lksw
cted agen
Prote AG.
– Pull 2-pin connector -2- off valve.

Passat 1997 ➤
Motronic injection and
wage
n AGignition
. Volkswagsystem
en AG (5-cyl. 4-valve) - Edition 11.2009
doe
ks s no
Vol t gu
by ara
– Connect therisdiode
ed test lamp -V.A.G 1527- using adapternte ca‐
bles fromuth-V.A.G
o 1594- to detached connector. The LED eo
ra
shouldssflash.
a c
ce
e
nl
LED flashes:
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Checking variable valve timing: ⇒ Rep. Gr. 15; Repairing
valve gear; Checking variable valve timing .
rrectness of i
LED does not flash:
l purpos
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Check line of valve -2- for open circuit between test box socket
115 and 2-pin connector contact 2 using current flow diagram.
earth. Specification: ∞ Ω.
memory.
Actuate vacuum pump for brakes -V192- :
Brake servo vacuum system
olkswagen AG
en AG. V
The brake servo orelay ksw -J569- activates the evacuum
ag do s
not pump for
V l
brakes -V192- d b , and this runs until the next control
y gu element is ac‐
ara
tivated by ise
rpressing the → button. nte
ho t e or
au ac
If vacuum
ss pump for brakes -V192- does not start up:
ce
e
nl
pt
– Check vacuum pump actuation: ⇒ Brake systems, Rep. Gr.

du
an
itte
47 .
y li
erm
ab
ility
If vacuum pump runs:

ot p
wit
, is n
h re
hole
spec
Actuate injectors ( -N30- ...N83):

es, in part or in w
t to the co
rrectness of i

l purpos
Injector, cylinder 1 N30
– If → button is pressed again, injector is actuated five times.

nform
ercia
To actuate injectors, cylinders 2...5, proceed in each case as for

m
at
om
actuation of injector 1.
ion
c
in t
or
Skipping individual tests is not possible, but final control diagnosis

his
ate
can be aborted by pressing the C button.

do
priv
cum
or
If one or more valves do not click:

f
en
ng
t.
yi Co
op
– Press the C button to end final control diagnosis. C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.

– Check relevant injector ⇒ page ⇒ page 113 .

wage es n
Passat 1997 ➤ yV
olks ot g
b ua
Motronic injection and ignition system (5-cyl.
ir se
d 4-valve) - Edition 11.2009 ran
tee
tho
u or
a ac
ss
ce
le
Note
un
pt
an
d
itte
y li
rm
ab
After completion of final control diagnosis, switch off ignition. If
pe
ility
the ignition is not switched off before attempting to start, the en‐
ot
wit
, is n
gine cannot run, as the injectors and the ignition transformer will
h re
not be activated.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
4 Readiness code
Function
The readiness code is an 8-digit numerical code which indicates
the status of the exhaust emission-relevant diagnoses.
The readiness code is deleted whenever the fault memory is
erased or on interruption of the voltage supply. Therefore, only
clear the fault memory if a fault is stored.
If diagnosis has been carried out successfully for a system (e.g.
secondary air system), the corresponding numerical code digit is
set from 1 to 0.
During normal vehicle operation, the diagnoses are carried out at
regular intervals. Following a repair on an exhaust emission-rel‐
evant system, generating the readiness code is recommended
but not yet legally prescribed.
If the engine control unit, the throttle valve module or the elec‐
tronic throttle have been renewed in vehicles with automatic
gearbox, the kick-down point must be taught-in again
⇒ page 151 .
4.1 Reading out readiness code

Volkswa AG. gen AG
agen does
♦ Fault reader -V.A.G 1551- V(or
olksvehicle system tester -
w not
gu
y
V.A.G 1552- ) with cable
se
d -V.A.G 1551/3-
b ara
nte
ri
Procedure: utho eo
ra
a c
ss
ce
e
nl
pt
du

an
itte
y li

erm
ab
⇒ page 4 )
ility
ot p
wit
, is n

h re
Select function XX
hole
spec
es, in part or in w
– Press buttons 1 and 5 for function “Readiness code” and

t to the co
confirm entry with Q button.

If all diagnoses have been carried out successfully, display must
rrectness of i
indicate:
l purpos
Indicated on display: Readiness code -

>
00000000 - Test complete
nf
ercia
or
m
m
atio
om

n in
or c

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
Appears on display:
t.
yi Co Readiness code -
op py
t. C rig>
gh 00101101 - Test not complete
ht
pyri by
Vo
co lksw
One of the diagnoses has not been completed successfully:
by
cted agen
Prote AG.
– Generate readiness code ⇒ page 44 .
Significance of 8-digit number block for readiness code:
The readiness code is only generated when all display digits are 0
1 2 3 4 5 6 7 8 Diagnostic function
4. Readiness code 43
Passat 1997 ➤
The readiness code is only generated when all display digits are 0
0 Catalytic converter
0 Catalytic converter heating (currently no diagnosis/always “0”)
0 Activated charcoal filter system (tank vent system)
0 Secondary air system
0 Air conditioner (currently no diagnosis/always “0”)
0 Lambda probes
0 Lambda probe heatingAG. Volkswagen
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0 Exhaust gas Vrecirculation
olks (not available/always
es n
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4.2 Generating readiness code
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
♦ Fault reader -V.A.G 1551- (or vehicle system tester -
ot
V.A.G 1552- ) with cable -V.A.G 1551/3-
wit
, is n
h re
hole
Test prerequisites
spec
es, in part or in w
• Vehicle stationary
t to the co
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
rrectness of i
must be switched off.
l purpos
• The coolant temperature must be 5 ... 95°C. ⇒ Display group

04, display zone 3
nform
ercia
• Intake air temperature below 60°C ⇒ Display group 04, display

m
a
zone 4
com
tion in
Procedure:
r
te o
thi
s
iva
do

r
rp
cum

fo
en
g

n
t.
yi Co
⇒ page 4 ) Cop py
t. rig
gh ht
yri
Step 1: Read fault memory p by
co Vo
by lksw
cted agen
Indicated on display: Prote AG.
Select function XX
– Press buttons 0 and 2 for function “Read fault memory” and

The number of faults stored or “No fault recognised!” will be X Faults recognised!
shown on the display.
If a fault is stored:
– Rectify faults printed out using fault table: SAE P0 or P2 codes
⇒ page 10 , SAE P1 or P3 codes ⇒ page 17
If no fault is stored:
– Continue with step 3.
Step 2: Erase fault memory
Select function XX
– Press keys 0 and 5 for function “Clear fault memory” and


AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
eo Passat 1997 ➤
ut
ss a Motronic injection and ignition system
ra
c (5-cyl. 4-valve) - Edition 11.2009
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
The readiness code is reset or deleted whenever the fault mem‐
, is n
h re
ory is cleared.
hole
spec
es, in part or in w
t to the co
Rapid data transfer ->
Fault memory is cleared!
rrectness of i
Note
l purpos
If the ignition is switched off between “Read fault memory” and

“Clear fault memory” the fault memory will not be cleared.
nform
mercia
at
om
ion
c
in t
or
Step 3: Adapt throttle valve module to engine control unit
his
ate
do
riv
p
cum
or

f
Select function XX
en
ng
t.
yi Co
op
– Press keys 0 and 4 for function “Initiate basic settings” and
C py
t. rig
gh ht
confirm entry with Q key. yri
p by
o Vo
by c lksw
cted agen
Basic setting
Input display group number XXX
– Press keys 0 , 6 and 0 for “Display group number 60” and

Indicated on display: (1…4 = display zones) System in basic setting 60 ->
xxx % xxx % x ADP. running
– Check specifications in display zones 3 and 4: Display zone

3: 0...8 Display zone 4: ADP. running, ADP. OK
xxx % xxx % 8 ADP. OK
– End adaptation after 30 seconds at the earliest by pressing →

button.
– Start engine and select engine control unit with “Address word”
⇒ page 4 )
Select function XX

Indicated on display: Basic setting
Note
♦ Steps 4 and 5 must be carried out during a road test.

♦ After the road test, the engine must not be switched off for the
further procedures.
♦ During certain steps, it may occur that a subsequent diagnosis
has already been carried out successfully in the background.
In this case, continue with the subsequent step.
Passat 1997 ➤

⇒ page 89 .
Observe test conditions ⇒ page 44 .
Step 4: Knock control diagnosis
Indicated on display: (1…4 = display zones) System in basic setting 203 -
>
1 2 3 4
– Accelerate vehicle in first gear until an engine speed of approx.

2500 rpm is reached.
– Allow engine to run briefly at approx. 2500 rpm until specifi‐
cation: x x x x x 1 0 0 is displayed in display zone 4.
If the display does not indicate as described:
AG. Volkswagen AG d
– Press → button. lksw
agen oes
not
o
byV gu
ara
– Read fault memory ⇒ page 8 . rised
nte
ho eo
ut
If the display indicates as described: ss a ra
c
ce
le
– Press button 3 (V.A.G 1551) or button ↑ (V.A.G 1552).

un
pt
an
d
itte
y li
Step 5: Vehicle speed diagnosis
rm
ab
pe
ility
Indicated on display: (1…4 = display zones)
ot
System in basic setting 204 -
wit
, is n
>
h re
1 2 3 4
hole
spec
– Accelerate vehicle until an engine speed of over 3000 rpm is
es, in part or in w
t to the co
reached.
– Then close throttle abruptly. Specification following overrun in
display zone 4: x x x x x 1 0 0
rrectness of i
l purpos
Note
nform
ercia
“Overrun” display must be achieved once for approx. three sec‐

m
onds. Drive in 1st gear to do this.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
– Read fault memory ⇒ page 8 . Cop
yi Co
py
ht. rig
If the display indicates as described: rig ht
py by
co Vo
by lksw
– Press button 3 (V.A.G 1551) or button ↑ (V.A.G 1552). Prote
cted AG.
agen
Step 6: Lambda probe heating before catalytic converter diagno‐

sis
Note
The following steps can be carried out with the accelerator and
brake pedals depressed constantly.
– Allow engine to idle.

>
1 2 3 4
– Depress brake pedal and hold.

– Depress accelerator to full throttle position.

Passat 1997 ➤
Engine revolutions are raised by engine control unit to approx.

1800 rpm.
– Allow engine to run at increased speed until specification: x x
x x x 1 0 0 is displayed in display zone 4.
– Read fault memory ⇒ page 8 .
If the display indicates as described:
– Press the C button.
Step 7: Inlet camshaft position versus crankshaft
wage
n AGdiagnosis
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doe
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Indicated on display: ed by ara setting
Basic
ris nte display group number XXX
Input
utho eo
ra
a c
– Press keys 2 , 0 and 8 for
ss “Display group number 208” and
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
>
ot p
1 2 3 4
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1800 rpm.
rrectness of i
l purpos
nform
ercia
m
at
om

ion
c
in t
or

his
ate
do
riv

p
cum
for
en
g
Step 8: Exhaust camshaft position versus crankshaft diagnosis

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
lksw >
by 1 2 3 4
cted agen
Prote AG.
1800 rpm.
Step 9: Variable valve timing (inlet) diagnosis
>
1 2 3 4
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Passat 1997 ➤ rise
d b ara
nte
Motronic injection andaignition
ut
ho
system (5-cyl. 4-valve) - Edition 11.2009 eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
1800 rpm. , is n
h re
hole
spec
x x x 1 0 0 is displayed in display zone 4 after approx. 40 sec‐
es, in part or in w
t to the co
onds.
rrectness of i
l purpos

nform
ercia

m
at
om
io
Step 10: Variable valve timing (exhaust) diagnosis
n
c
in t
or
his
e

at
do
riv
>
p
cum
or
1 2 3 4
f
en
ng
t.
yi Co
– Depress brake pedal and hold. t. Cop py
rig
gh ht
– Depress accelerator to full throttle position. pyri by
Vo
co lksw
by
cted agen
Engine revolutions are raised by engine control unit to approx. Prote AG.
1800 rpm.
onds.
Step 11: Lambda probe ageing before catalytic converter (probe
dynamics) diagnosis
>
1 2 3 4

1800 rpm.
onds.

olkswagen AG Passat 1997 ➤
en AG. V
Motronic
olksw injection
ag and ignition
doesystem
s no
(5-cyl. 4-valve) - Edition 11.2009
yV t gu
db ara
rise nte
tho eo
Note s au ra
c
s
ce
le
un
pt
During this step, it may occur that the catalytic converter is no
an
d
itte
y li
longer at the required temperature. Therefore, switch to “Reading
rm
ab
measured value block” mode and then to display group 046. Run
pe
ility
the engine at approx. 3500 rpm to bring the catalytic converter
ot
wit
, is n
temperature to at least 350°C and repeat this step ⇒ page 48 .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Step 12: Fuel supply system diagnosis (part throttle)
l purpos
nform
ercia

m
a
com
tio
n in
r
te o
thi
s
iva
do
r
>
rp
cum
1 2 3 4
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
– Depress accelerator to full throttle position. yri
p by
co Vo
by lksw
cted
agen
Prote AG.
1800 rpm.
onds.
Step 13: Air mass charge detection diagnosis

>
1 2 3 4

1800 rpm.
Passat 1997 ➤
Note
This procedure may take approx. 4 minutes.

n AG. Volkswagen AG
age does
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If the display does inot ed indicate as
b described: ara
nte
ors eo
h
au
t ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Step 14: Lambda probe heating after catalytic converter diagnosis
h re
hole
spec
es, in part or in w
Basic setting
t to the co

rrectness of i
l purpos

>
1 2 3 4
nform
ercia

m
at
om
– Depress accelerator to full throttle position. ion

c
in t
or

his
ate
1800 rpm.
do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Press → button. cted agen
Prote AG.

Step 15: Lambda probe after catalytic converter diagnosis

>
1 2 3 4

1800 rpm.
onds.

Passat 1997 ➤

Step 16: Lambda probe ageing after catalytic converter (probe
dynamics) diagnosis

>
1 2 3 4

1800 rpm.
onds.
– Press the C button. agen
AG. Volkswagen AG d
oes
olksw not
Step 17: Catalytic converter diagnosis byV gu
ara
ed
ris nte
o eo
Indicated on display: aut
h Basic setting ra
ss Input display group number XXX c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
>
h re
1 2 3 4
hole
spec
es, in part or in w
t to the co
Engine revolutions are raised by engine control unit to approx. rrectness of i
1800 rpm.
l purpos

onds.
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
op
– Press the C button. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Note Prote AG.
After this step, the engine control unit restores idling speed status.
Passat 1997 ➤
– Release accelerator and brake pedals.

– Allow engine to idle.
Step 18: Fuel supply system diagnosis (idling speed)

>
1 2 3 4
– Allow engine to run at idling speed until specification: x x x x x

1 0 0 is displayed in display zone 4 after approx. 30 seconds.
– Read fault memory ⇒ page 8 . AG. Volkswagen AG d
agen oes
ksw
If the display indicates as described: byV
ol not
gu
ara
ed
is nte
– Press the C button. hor eo
aut ra
s c
Step 19: Activated charcoal filter system (tank vent system) di‐ s
ce
e
agnosis
nl
pt
du
an
itte
y li
erm
ab
Basic setting
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
>
1 2 3 4
rrectness of i
l purpos
nform
ercia
m
– Read fault memory ⇒ page 8 . at

om
ion
c
in t
r

o
his
ate
do
riv

p
cum
for
en
Step 20: Secondary air system diagnosis

ng
t.
yi Co
op py
. C rig
ht Basic setting ht
rig by
copy Input display group number XXX
Vo
by lksw
cted agen
Prote AG.

>
1 2 3 4


Passat 1997 ➤
wage es n
– Read readiness code y V out ⇒ page 43 .
olks ot g
ua
b
ed ran
thoris tee
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Passat 1997 ➤
5 Measured value blocks
5.1 Safety precautions

Observe following if test and measuring instruments are required
during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
5.2 Reading measured value block

♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3-
Test prerequisites
• Coolant temperature must be at least 80 °C, ⇒ display group
04, display zone 3.
• If the vehicle is equipped with an air conditioner, it must be
switched off.
• On vehicles with automatic gearbox the selector lever must be
in “P” or “N” position.
• No faults must be stored in fault memory ⇒ page 8 , interrog‐
agen
AG. Volkswagen AG d
oes
ating fault memory. olksw not
yV gu b ara
ed
Procedure: horis nte
e
t or
au ac
– Connect fault reader -V.A.G 1551- (V.A.G engine 1552).
ss Start
and select “Address word” 01 of engine control unit. (Connect ce
e
nl
pt
du
fault reader and select engine control unit ⇒ page 4 ) an

itte
y li
erm
ab
Indicated on display: Rapid data transfer
ility
HELP
ot p
Select function XX
wit
, is n
h re
– Press keys 0 and 8 for function “Read measured value block”

hole
spec
and confirm entry with Q key.

es, in part or in w
t to the co
Indicated on display: Read measured value block HELP

rrectness of i
– Select required display group number.

l purpos
Note
nform
ercia
The display group number 1 is an example, to illustrate the se‐

m
at
quence.
om
ion
c
in t
or
his
e

at
do
riv

p
cum
for
en
g

n
t.
yi Read measured value block 1 Co ->
op py
t. C 1 2 3 rig 4
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
Note
To change to another display group proceed as follows:
Display group -V.A.G 1551- -V.A.G 1552-

Higher Press key 3 Press ↑ key
Lower Press key 1 Press ↓ key
Skip Press C key Press C key
– If the specifications are achieved in all display zones, press

→ button.

Select function XX
– Press keys 0 and 6 for function “End data transfer” and con‐
firm entry with Q key.
Note
Measured value blocks which are not described in this chapter

are currently only intended for development and production. The
values displayed are not relevant for fault finding within the serv‐
ice department.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Measured value blocks 55

Passat 1997 ➤
6 Evaluating measured value blocks, display groups 0...8 -basic func‐

tions-
Display group 001 -Basic functions-
• Engine running at idling speed
Read measured value block → ▾ Indicated on display

1
xxxx xx.x°C x.x% xxxxxxx
rpm x
1 2 3 4 ▾ Display zones Specification Evaluation
Adjustment conditions for ba‐ 1x111111 ⇒ page 56
sic setting
Lambda control before catalytic convert‐ -10.0...10.0 % ⇒ page 67
er
Coolant temperature 80…110 °C ⇒ page 59
Engine speed (idling speed) 650...750 rpm ⇒ page 56
Significance of 8-digit number block

Significance if display = 1
1 2 3 4 5 6 7 8 Significance
1 Coolant temperature above 80°C
1 Speed below 2000 rpm
1 Throttle valve closed
1 Lambda control OK
wage
1 Idling switch closed olks es n
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byV ua
1 Air conditioner compressor
o
ir se
d
switched off ran
tee
th or
X Not relevant s au ac
s
1 No fault recognised by self-diagnosis
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Evaluating display group 1, display zone 1 - Engine speed (idling

wit
, is n
speed)
h re
hole
spec
Display - Possible cause of fault Fault remedy

es, in part or in w
V.A.G 1551-
t to the co
Less than 650 rpm ♦ Throttle valve control module sticking or – Checking throttle valve control module
defective ⇒ page 99
rrectness of i
♦ Large amount of unmetered air (cannot – Check intake system for leaks
l purpos
be compensated for by idling stabilisa‐ ⇒ page 124

tion)
nform
ercia
More than 750 rpm ♦ Idling switch not closed or defective – Read fault memory, ⇒ page 8
m
at
om
ion
♦ Large amount of unmetered air (cannot – Check intake system for leaks
c
in t
or
be compensated for by idling stabilisa‐ ⇒ page 124

his
ate
tion)
do
priv
cum
for
♦ Throttle valve control module sticking/ – Checking throttle valve control module
en
ng
t.
yi Co
defective t. Cop ⇒ page 99 py
rig
gh ht
yri by
♦ Supply voltage too low, engine tries to – Checking alternator ⇒ page 58
cop Vo
by lksw
reduce charge difference through in‐ cted agen
Prote AG.
creased idling speed

Passat 1997 ➤
Display - Possible cause of fault Fault remedy

V.A.G 1551-
♦ Air conditioner operating too long at – Switch off air conditioner
idling speed
Display group 2 -Basic functions- Air mass meter


2
xxxx xxx % x.x ms x.x g/s
rpm
1 2 3 ▾ Display zones 4 Specification Evaluation
Intake air mass 3.0…5.0 g/s ⇒ page 57
Injection period 1.0…4.0 ms ⇒ page 57
Engine load 12...26 % ⇒ page 61
Engine speed (idling speed) n AG. Volkswagen AG
650...750 rpm ⇒ page 56
age does
ksw not
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ed nte
oris eo
Note on display zone 4: au
th
ra
ss c
♦ The air mass measured by the air mass meter is displayed.
ce
le
un
pt
an
d
Evaluating display group 2, display zone 3 - Injection period

itte
y li
erm
ab
ility
Indicated on display Possible cause of fault Fault remedy
ot p
wit
is n
Less than 1.0 ms ♦ Large amount of fuel from the activated – Checking activated charcoal filter sole‐
h re
ole,
charcoal filter system noid valve 1 ⇒ page 29 , final control
spec
diagnosis
t to the co
♦ Incorrect injectors with greater through‐ – Checking injection rate ⇒ page 113
put installed
rrectne
More than 4.0 ms ♦ Increased engine load due to electric – Eliminate increased load (air condition‐
consumers, air conditioner, gear selec‐ er, power-assisted steering etc.)
ted or power steering on full lock ss o
cial p
f inform
mer
atio
m
Evaluating display group 2, display zone 4 - Air mass drawn in

o
n
c
i
or
n thi
e

t
sd
iva
o
pr
Less than 3.0 g/s ♦ Large amount of unmetered air between – Eliminate unmetered air
um
r
fo
en
ng
intake manifold and air mass meter yi

t.
Co
Cop py
t. rig
More than 5.0 g/s ♦ Gear selected (automatic gearbox) gh
– Place selector lever in P or N
ht
pyri by
Vo
o
by c lksw
cted
♦ Engine loaded due to ancillaries – Eliminate load (air conditioner, power-
agen
Prote AG.
assisted steering etc.)
Display group 3 -Basic function- Air mass meter


3
xxxx x.xx g/s x.x% xx.x°
rpm BTDC
6. Evaluating measured value blocks, display groups 0...8 -basic functions- 57

Passat 1997 ➤

Ignition angle 9...15° BTDC ---
Throttle valve angle (potentiometer 1 - 0.2...4.0 % ⇒ page 61
G187- )
Intake air mass 3.0…5.0 g/s ⇒ page 57
Note on display zone 3:

♦ Display value must be approx. 100% when accelerator is fully AG. Volkswagen AG d
agen
depressed. Volksw
oes
not
y gu
db ara
Display group 4 -Basic functions- rise nte
tho eo
au ra
• Engine running at idling speed ss c
ce
e
nl
pt
du
an
itte
y li
4
erm
ab
ility
xxxx xx.xxx V xxx.x°C xxx.x°C
ot p
rpm
wit
, is n
h re
hole
spec
Intake air temperature -48...143.0°C ⇒ page 59
es, in part or in w
t to the co
Coolant temperature 80…110°C ⇒ page 59
Voltage supply for engine control unit 12.0...15.0 V ⇒ page 58
rrectness of i
l purpos
nf
ercia
orm
m
♦ The engine control unit will use the intake air temperature as
atio
m
a replacement value to start the engine (starting temperature

o
n in
or c
substitute value) as soon as a fault is stored in the fault mem‐
thi
e
ory, which affects the coolant temperature sender -G62- . The

t
sd
iva
o
temperature then rises according to a model stored in the con‐
r
rp
cu
o
m
trol unit. When the engine has reached normal operating
f
en
ng
t.
temperature a fixed substitute value will be displayed after a
yi Co
op
certain period. This fixed substitute value is in turn dependent
C py
t. rig
gh
upon the intake air temperature.
ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
♦ The entire temperature range is specified as the specification.

The display value must exceed the ambient temperature.
Evaluating display group 4, display zone 2 - Control unit supply
voltage
Less than 12.0 V ♦ Alternator defective, battery heavily dis‐ – Check alternator and battery voltage,
charged charge battery: ⇒ Electrical system
♦ Severe battery load shortly after starting – Increase revs slightly for a few minutes
due to high charging current and ancil‐ and switch off additional consumers
laries
♦ Transfer resistance in the current supply – Checking control unit voltage supply
or the engine control unit earth connec‐ ⇒ page 138
tion
♦ Current draw when ignition is off – Eliminate current draw

Passat 1997 ➤

More than 15.0 V ♦ Voltage regulator on alternator defec‐ – Check voltage regulator, renew if nec‐
tive essary: ⇒ Electrical system
♦ Excess voltage due to jump starting or – Read fault memory ⇒ page 8 .

AG. Volkswagen AG dunit
agen quick charging oes
olksw not
y V gu
db ara
rise nte
tho eo
s au ra
c
s
Evaluating display group 4, display zone 3 - Coolant temperature
ce
e
nl
pt
du
an
itte
y li
erm
ab
Less than 80°C ♦ Engine too cold – If necessary carry out road test
ility
ot p
wit
, is n
♦ Coolant temperature sender or line to – Check coolant temperature sender
h re
hole
engine control unit ⇒ page 104
spec
es, in part or in w
t to the co
More than 110°C ♦ Radiator soiled – Clean radiator
♦ Radiator fan does not function – Check function: ⇒ Electrical system
rrectness of i
♦ Thermostat defective – Checking thermostat ⇒ Rep. Gr. 19;
l purpos
Removing and installing parts of cooling

system; Parts of cooling system, en‐
nf
gine-side
ercia
orm
♦ Coolant temperature sender or line to – Check coolant temperature sender
m
atio
m
engine control unit defective ⇒ page 104

o
n in
or c
thi
e
Constant -48.0°C ♦ Wiring open circuit – Check coolant temperature sender

t
sd
iva
⇒ page 104
o
r
rp
cu
o
Constant 143.0°C ♦ Short-circuit between lines 1 and 3

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Evaluating display group 4, display zone 4 - Intake air tempera‐
Prote AG.
ture
Constant -48.0°C ♦ Wiring open circuit – Check intake air temperature sender
⇒ page 108
Constant 143.0°C ♦ Short-circuit between lines 1 and 2
Display group 5 -Basic function-


5
xxxx xxx % xxx km/h Text
rpm
1 2 3 ▾ Display zones
4 Specification Evaluation
Operating status (idling, part Idling ---
throttle, enrichment, overrun)
Road speed 0 km/h ---
6. Evaluating measured value blocks, display groups 0...8 -basic functions- 59

Passat 1997 ➤
Display group 6 -Basic function-


6
xxxx xxx % xxx.x°C xx.x%
rpm
Altitude correction factor Volkswa -50.0...20.0 % ---
en AG. gen AG
Intake air temperature olkswag -48...143.0°C
does
not ⇒ page 59
V gu
by
Engine load ris
ed 12...26 % ara
nte ⇒ page 61
ho eo
Engine speed (idling speed) sa
ut
650...750 rpm ⇒r acpage 56
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ The entire temperature range is specified as the specification.
wit
, is n
The display value must exceed the ambient temperature.
h re
hole
spec
es, in part or in w
t to the co
The altitude specifications listed here are starting points only.
♦ 0% = 0 m altitude
rrectness of i
♦ -10% = 1000 m altitude
l purpos
♦ -20% = 2000 m altitude

Vehicles with automatic gearbox
nform
ercia
Display group 8 -Basic function- Vacuum pump for brakes

m
at
om
io
n
c
in t
or
his
ate
• Control unit in mode 04 -Basic setting
do
priv
cum
for
– Depress brake pedal several times

en
ng
t.
yi Co
op
Read measured value block → ▾ Indicated on display C py
t. rig
8
gh ht
pyri by
Vo
o
by c
Text Text mbar Text
lksw
cted agen
Prote AG.
Result of vacuum pump for Syst. OK ---
brakes short test (Test on /
Test off / Sys. OK. / Sys.
n.OK.)
Press brake servo --- ---
Status of vacuum pump for brakes (pump on, --- ---
pump off)
Status of brakes (operating, operated, not operated) --- ---

Passat 1997 ➤
Motronic
wagen AG. injection
Volkswagenand
AG dignition
oe system (5-cyl. 4-valve) - Edition 11.2009
ks s no
Vol t gu
d by ara
e nte
ris
7 Evaluating measured value blocks, display groups 10...29 -Ignition-
au
tho eo
ra
ss c
ce
Display group 10 -Ignition-
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
10
h re
hole
xxxx xxx % x.x% xx.x°
spec
rpm BTDC
es, in part or in w
t to the co
Ignition angle 9...15° BTDC ---
rrectness of i
Throttle valve angle (potentiometer 1 - 0,2...4,0 % ⇒ page 61
G187- )
l purpos

nform
mercia
a
com
tion in
r

te o
thi
s
iva
do
♦ Display value must be approx. 100% when accelerator is fully
r
rp
cum
depressed.
fo
en
ng
t.
yi Co
Evaluating display group 10, display zone 2 - Engine load t. Cop py
rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Less than 12% Prote
♦ Lesser values can only occur when driv‐
AG.
ing in overrun
More than 26% ♦ Rough idling (not running on all cylin‐ – Checking injectors and ignition system
ders)
♦ Injectors or spark plugs defective
♦ Electrical consumers on – Switch off electrical consumers
♦ Steering wheel at full lock – Set steering wheel to centre position
♦ Gear selected (automatic gearbox) – Place selector lever in P or N
♦ Air mass meter defective – Check air mass meter ⇒ page 96
Evaluating display group 10, display zone 3 - Throttle valve angle

More than 4% ♦ Engine control unit not adapted to throt‐ – Adapting engine control unit to throttle
tle valve module valve module ⇒ page 143
♦ Throttle valve potentiometer in throttle – Checking throttle valve control module

valve control module defective ⇒ page 99
♦ Throttle valve sticking – Rectify cause
Display group 14 -Ignition- Misfiring detection


14
7. Evaluating measured value blocks, display groups 10...29 -Ignition- 61

Passat 1997 ➤
xxxx xxx % xxx Text

rpm
1 2 ▾ Display zones
3 4 Specification Evaluation
Misfiring detection (activated, Activated ⇒ page 62
blocked)
Total misfires 0 ---

♦ The total misfires detected are displayed here. No statement
is made about the time during which the misfires occurred.
Therefore, check misfiring detection during vehicle operation
⇒ page 166 .
Evaluating display group 14, display zone 3 - Total misfires
Greater than 5 ♦ Spark plug defective – Checking ignition coils with output
stage ⇒ page 160
♦ Spark plug connector defective
♦ Ignition coil defective – Checking spark plugs and ignition
cables with connector
♦ Final output stages for ignition coil defective ⇒ page 154
♦ Injector defective – Checking injectors ⇒ page 113 .
Display group 15 -Ignition- Misfiring detection

AG. Volkswagebank
n AG d 1
agen oes
ksw
• Vehicle operation by V ol not
gu
ara
ed nte
ris
Read tho
measuredavalue block → ▾ Indicated on display e or
u ac
15 ss
ce
le
x x x Text
un
pt
an
d
itte

y li
erm
ab
Misfiring detection status Activated ---

ility
ot p
blocked
wit
is n
h re
Exhaust emission-harming misfiring, 0...2 ---

ole,
spec
cyl. 3
t to the co
Exhaust emission-harming misfiring, cyl. 2 0...2 ---

rrectnes
Note on display zones 1 to 3:

s o
cial p
♦ The detected misfires should be 0. If the specification is ex‐

inform
ceeded, evaluation ⇒ page 168 .

mer
atio
m
Display group 16 -Ignition- Misfiring detection bank 2

o
n
c
i
or
• Vehicle operation
thi
te
sd
iva
o
pr

um
r
fo
en
ng
16
t.
yi Co
op
x x x Text
C py
ht. rig
rig ht
by
copy Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
Misfiring detection status Activated ---

blocked
--- ---
Note on display zones 1 to 2:

♦ The detected misfires should be 0. If the specification is ex‐
ceeded, evaluation ⇒ page 168 .
Display group 22 -Ignition- Knock control

22
xxxx x.xx% xx.x° CA xx.x° CA
rpm
Cyl. No. 2 retardation of igni‐ 0…12.0° CA ⇒ page 64
tion timing by knock control
Cyl. No. 1 retardation of ignition timing 0…12.0° CA ⇒ page 64
by knock control . Volkswage
n AG n AG d
Engine load wage oes
10...100 % ---
Volks not
gu
by ara
Engine speed or
ised
650...6500
nte rpm ---
th eo
au ra
c
ss
ce
le
un
Note on display zones 3 and 4: pt

an
d
itte
y li
erm
♦ The displayed value should be 0.0° CA at idling speed. ab

ility
ot p
wit
is n
h re
ole,
spec
t to the co

23
xxxx x.xx% xx.x° CA xx.x° CA
rrectne
rpm
ss
Cyl. No. 4 retardation of igni‐ 0…12.0° CA ⇒ page 64

o
cial p
f i
tion timing by knock control

nform
mer

atio
m
by knock control
o
n
c
i
or
Engine load 10...100 % ---

thi
te
sd
a
Engine speed 650...6500 rpm ---

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
.
Note on display zones 3 and 4:
ht rig
rig ht
py by
co Vo
♦ The displayed value should be 0.0° CA at idling speed.
by lksw
cted agen
Prote AG.


24
xxxx x.xx% xx.x° CA
rpm
7. Evaluating measured value blocks, display groups 10...29 -Ignition- 63

AG. Volkswagen AG d
agen oes
o lksw not
V gu
d by ara
e nte
Passat 1997 ➤ horis
eo
ut
Motronic injection
ss a and ignition system (5-cyl. 4-valve) - Editionra
c11.2009
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
by knock control
, is n
h re
hole
Engine load 10...100 % ---
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ The displayed value should be 0.0° CA at idling speed.

Evaluating display groups 22...24, display zones 3 and 4 - Retar‐
nf
ercia
dation of ignition
orm
m
atio
om
n in
or c
All cylinders 12° CA ♦ Knock sensor defective – Checking knock sensors
thi
te
⇒ page 163
sd
iva
o
r
rp
cu
♦ Connector corroded
o
m
f
en
ng
t.
yi Co
op
♦ Knock sensor incorrectly tightened – Loosen knock sensor and tighten
C py
t. rig
to 20 Nm
gh ht
pyri by
Vo
o
by c
♦ Loose components on engine – Secure loose components
lksw
cted agen
Prote AG.
♦ Poor fuel quality – Change type of fuel
One cylinder devi‐ ♦ Connector corroded – Checking knock sensors

ates greatly from ⇒ page 163
the others
♦ Mechanical engine fault – Checking compression pressure:
⇒ Rep. Gr. 15; Removing and in‐
stalling cylinder head; Checking
compression pressure
♦ Loose components on engine – Secure loose components


28
xxxx xx.x% xxx.x°C Text
rpm
Result of knock sensor test Syst. OK ---
(Test on / Test off / Sys. OK. /
Sys. n.OK.)
Engine load 10...100 % ---

Passat 1997 ➤
Motronic injection and
. Volkswage
ignition system (5-cyl. 4-valve) - Edition 11.2009
AG n AG d
agen oes
olksw not
yV gu
db ara
8 Evaluating measured value blocks, display groups 30...33, 99 -Lamb‐
tho
rise nte
eo
da control- au ra
ss c
ce
le
un
pt
Display group 30 -Lambda control status-
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
30
ole,
spec
xxx xxx
t to the co
rrectne
Lambda probe status, probe 2 bank 1 after cata‐ 111 ⇒ page 65
lytic converter
ss o
Lambda probe status, probe 1 bank 1 before catalytic con‐ 111 ⇒ page 65
cial p
f in
verter
form
mer
atio
om
n
c
i
or
n
Significance of 3-digit number block in display zone 1:
thi
te
sd
iva
o
r
p
cum
r
fo
en
ng
1 2 3
t.
yi Co
op py
1 Lambda control active
t. C rig
gh ht
yri by
1 Lambda probe operational
cop Vo
by lksw
cted agen
Prote
1 Lambda probe heating on
AG.
Note
♦ Depending on status of Lambda control, 0 or 1 may be alter‐

natingly displayed in 3-digit number block, but Lambda probe
must always be operational.
♦ The 1 set for Lambda probe heating may also occasionally be
0 because the probe heating is pulsed.
Display group 32 -Lambda control- Lambda learnt values


32
xx.x% xx.x%
Probe 1, bank 1 Lambda learnt value at part throt‐ -10...10 % ⇒ page 66

tle (mul.)
Probe 1, bank 1 Lambda learnt value at idling speed (add.) -5,4...5,4 % ⇒ page 66
8. Evaluating measured value blocks, display groups 30...33, 99 -Lambda control- 65

Passat 1997 ➤
Note
♦ Low values indicate that the engine is running too rich and
Lambda control is therefore leaning the mixture.
♦ High values indicate that the engine is running too lean and
Lambda control therefore enriches the mixture.
♦ If there is no voltage supply to the control unit all the values
learnt will be reset.
♦ add = additive - The effects of the fault (e.g. unmetered air)
will reduce as the engine speed increases. The injection peri‐
od will be modified by a fixed amount for additive learnt values.
This amount is not dependent upon the basic injection period.
♦ mul = multiplicative - The effects of the fault (e.g. faulty injec‐
wage
e
tor) will increase as the engine speed increases. A multiplica‐
Vol
ks s no
t gu
by
tive learnt value is a proportional change to the injection
ed ara
nte
ris
period. This change is dependent on the basic injection
ut
ho period. eo
ra
a c
ss
ce
Initiating learning process: Control unit in mode 04, basic setting
e
nl
pt
du
an
itte
♦ Learning conditions for idling speed: Idling speed, coolant
y li
erm
ab
temperature min. 75°C, intake air temperature max. 90°C
ility
ot p
wit
Evaluating display group 32, display zones 1 to 4 - Lambda learnt
, is n
h re
values-
hole
spec
es, in part or in w
t to the co
Low Lambda learnt ♦ Low learnt values at idling speed but – Disappears after motorway drive or oil
values normal learnt values at part throttle: pos‐ change
sible oil dilution (high level of fuel in oil)
rrectness of i
l purpos
♦ Injector leaking – Checking injectors ⇒ page 113
♦ Fuel pressure too high – Checking fuel pressure regulator and
nf
ercia
o
holding pressure ⇒ page 119 .
rm
m
atio
♦ Activated charcoal filter solenoid valve 1 – Checking activated charcoal filter sole‐
om
permanently open noid valve 1 ⇒ page 29 , final control

n in
or c
diagnosis thi
te
sd
iva
♦ Air mass meter defective – Check air mass meter ⇒ page 96

o
r
rp
cu
o
m
f
en
ng
♦ Lambda probe heating defective or – Checking Lambda probe heating

t.
yi Co
op
Lambda probe soiled ⇒ page 91
C py
t. rig
gh ht
pyri by
Vo
o
Continued on next page
c by lksw
cted agen
Prote AG.

High Lambda ♦ High learnt values at idling speed, not so – Check intake system for leaks
learnt values high learnt values at part throttle: possi‐ ⇒ page 124
ble unmetered air in area of intake mani‐
fold
♦ Unmetered air between air mass meter – Rectify cause

and throttle valve
♦ Injector blocked – Checking injection rate ⇒ page 113
♦ Display zones 1 and 3 high: Air mass – Check air mass meter ⇒ page 96
meter defective
♦ Fuel pressure too low – Checking fuel pressure regulator and

holding pressure ⇒ page 119 .

Passat 1997 ➤

♦ Unmetered air at exhaust manifold gas‐
ket
♦ Lambda probe heating defective or – Checking Lambda probe heating

Lambda probe soiled ⇒ page 91
Display group 33 -Lambda control- Lambda control values


33
xx.x% x.xxx V
Probe voltage Lambda probe 1 bank 1 1.400...1.600 V ⇒ page 67

Lambda control bank 1 -10.0...10.0 % ⇒ page 67
Evaluating display group 33, display zones 1 and 3

Outside tolerance ♦ Minus range: Mixture toowrich,
agen Lambda – AWait
AG. Volkswagen G d 30 seconds until the display has
oes
range control weakens mixture
yV
o lks stabilised
not
gu b ara
ed
♦ Positive range: riMixture
s too lean, Lamb‐ nte
tho e
da control senriches
au mixture or
ac
s
ce
e
nl
♦ Unmetered air – Check intake system for leaks pt

du
an
⇒ page 124
itte
y li
erm
ab
♦ Injector defective – Checking injection rate ⇒ page 113 ility
ot p
wit
, is n
♦ Lambda learnt values at limit – Check Lambda learnt value in display

h re
group 32
hole
spec
es, in part or in w
t to the co
Evaluating display group 33, display zones 2 and 4

rrectness of i

l purpos
Constant 1.5 V ♦ Wiring open circuit – Checking Lambda probe lines

⇒ page 131
nf
ercia
orm
m
atio
om
Display group 34 -Lambda control- Lambda probe before catalytic converter (ageing test) diagnosis
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
• Vehicle stationary, engine running at increased idling speed (with brake depressed and accelerator in
o
m
f
en
ng
full throttle position only)

t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
34
c by lksw
cted agen
Prote AG.
xxxx xxx.x°C xx Text
rpm

Passat 1997 ➤
Result of ageing test of Lamb‐ B1 -S1- OK ---

da probe before catalytic con‐
verter (Test OFF/Test ON/B1
-S1- OK / B1 -S1- n.OK)
Dynamic factor, Lambda probe before 0...8 ---
catalytic converter
Catalytic converter temperature Min. 350°C ---
Engine speed 1800 rpm ---

olkswagen AG
♦ Value calculated from engine speed
swa
and
gen AGload.
.V
does
olk not
y V gu
b
Display group 41 -Lambda riprobe
se
d heating before and after catalyticarconverter-
an
tee
ho
• Vehicle stationary, engine
aut running at idling speed or
ac
ss
ce
e
nl
pt
du
an
41
itte
y li
erm
ab
Text Text
ility
ot p
wit
, is n
h re
Lambda probe heating, probe Heat. after cat. ON ---
hole
spec
2, bank 1 (after catalytic con‐ Heat. after cat. OFF
es, in part or in w
verter) occasionally alter‐
t to the co
nating
rrectness of i
Lambda probe heating, probe 1, bank 1 Heat. bef. cat. ON ---
(before catalytic converter) Heat. bef. cat. OFF
l purpos
occasionally alter‐
nating
nform
ercia
--- ---
m
at
om
ion
c
in t
or
Display group 43 -Lambda control- Lambda probe after catalytic converter (ageing test) diagnosis
his
ate
do
riv

p
cum
for
en
ng
t.
yi
Co
op py
full throttle position only) t. C rig
gh ht
pyri by
Vo
co lksw
by
Read measured value block →
Prote
cted▾ Indicated on display
AG.
agen
43
xxxx xxx.x°C x.xx V Text
rpm
Result of ageing test of Lamb‐ B1 -S2- OK ---
da probe after catalytic con‐
verter (Test OFF/Test ON/B1
-S2- OK / B1 -S2- n.OK)
Probe voltage Lambda probe 2 bank 1 0.00...1.00 V ---

♦ Value calculated from engine speed and load.
Display group 46 -Lambda control- Catalytic converter (conversion test) diagnosis

Passat 1997 ➤
full throttle position only) G. Volkswagen nA AG do
wage es n
olks ot g
Read measured value block → ▾ bIndicated
y V on display ua
ed ran
46 oris tee
th or
xxxx xxx.x °C x.xx% Text
ss
au ac
rpm
ce
le
un
pt
an
d
itte
y li
rm
Result of catalytic converter Cat B1 OK ---
ab
pe
ility
conversion test
ot
wit
(Test OFF / Test ON / Cat B1
, is n
h re
OK / Cat B1 n.OK)
hole
spec
Catalytic converter efficiency At least 1% ---
es, in part or in w
t to the co
rrectness of i
l purpos
Display group 99 -Lambda control- Lambda control operating status

nform
mercia
a
• Control unit in mode 04-Basic setting, Lambda control off
com
tion in
r
te o
• Control unit in mode 08-Read measured value block, Lambda control on
thi
s
iva
do
r
rp
c
um
fo
en
g
99
n
t.
yi Co
op
xxxx xx.x°C x.x% Text
C py
t. rig
gh
rpm
ht
pyri by
Vo
co lksw
by
1 2 3 ▾ Display zones 4 Prote
cted AG. Specification
agen
Evaluation
Lambda control operating sta‐ λ cont. OFF or ---
tus λ cont. ON
Lambda control -10.0...10.0 % ⇒ page 67

♦ For defined fault finding, Lambda control is switched off when
selecting display group 99 under “Basic setting” or switched
on under “Read measured value block”. When the function 04
“Basic setting” is exited, Lambda control is automatically ac‐
tive again.
♦ It is possible to switch between the function 04 “Basic setting”
and the function 08 “Read measured value block” by pressing
buttons 4 and 8 on -V.A.G 1551/1552- .

Passat 1997 ➤
9 Evaluating measured value blocks, display groups 50...69 -Engine

speed regulation-
Display group 50 -Engine speed regulation- Operating statuses

50
xxxx xxxx rpm Text Text
rpm
Air conditioner compressor Compr. ON or ---
AG. Volkswagen AG d
operating statusksON/OFF
wagen Compr.oesOFF
not
ol
Air conditioner operating y V status A/C-High or gu
---
edb ara
thoris A/C-Low nte
e or
au
Engine speed (idling speed
ss specification): 700 rpm ac
---
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Notes on display zones 3 and 4:
wit
, is n
h re
♦ A/C-High = Air conditioner demands high heating or cooling
hole
spec
performance. A/C-Low = Air conditioner not turned on.
es, in part or in w
t to the co
♦ “Compr. OFF” is always displayed on vehicles without air con‐
ditioner.
rrectness of i
♦ Checking signals from and to air conditioner compressor
⇒ page 147
l purpos
Display group 54 -Engine speed regulation-
nf
ercia
orm
m
atio
m

o
n in
c
54
or
thi
e
xxxx Text xxx % xxx %

t
sd
iva
rpm
r
rp
cu
o
m
f
en
▾ Display zones Specification Evaluation

ng
1 2 3 4
t.
yi Co
op
Throttle valve angle (potenti‐ 0...100 % ---
C py
ht. rig
ometer 1 -G187- )
rig ht
py by
co Vo
by lksw
Accelerator position sender 1 -G79- Prote
cted AG.0...97 % agen
---
Operating status (idling speed, part throttle, en‐ --- ---
richment, overrun)
Notes on display zone 1:

♦ No further display on tester as of 2520 rpm
♦ The operating status is displayed according to engine speed
or load. At a higher engine speed, “overrun” is only displayed
when throttle valve is closed up to 1450 rpm, and then idling
speed again.
Display group 55 -Engine speed regulation- Idling speed stabilisation

Passat 1997 ➤

55
xxxx xx.xx% xx.xx% xxxxx
rpm
Operating
AG. Vstatus
olkswagen AG xxxxx ⇒ page 71
agen does
olksw
Idling yregulator learning value not -5,0...5,0 % ---
V gu
Airiseconditioner
db on (A/C-High) ara -5,0...5,0 %
nte
hAir
or conditioner off (A/C-Low) eo
aut ra
Idling speed
ss regulator -5.0...10.0
c
% ---
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
♦ The extent to which idling speed stabilisation has “moved
spec
away” from the prescribed average value is displayed. For a
es, in part or in w
t to the co
new engine, the value lies in the positive range, because of
the higher friction, and in the negative range with an engine
that has run-in.
rrectness of i
Significance of 5-digit number block
l purpos
1 2 3 4 5 Significance
nform
ercia
x Not relevant
m
a
com
tio
x Not relevant
n in
r
te o
thi
1 Air conditioning system switched on
s
iva
do
1 Driving range selected
r
rp
cum
fo
en
g
1 Air conditioner compressor switched on

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Display group 56 -Engine speed regulation- Idling speed stabilisation
agen
Prote AG.

56
xxxx xxxx rpm x.x% xxxxx
rpm
Operating status xxxxx ⇒ page 71
Idling speed regulator -5.0...10.0 % ---
Engine speed (idling speed specification): 700 rpm ---
Note
♦ The rpm in display zone 1 (measured rpm) is the actual engine

speed.
♦ The rpm in display zone 2 (specified rpm) is a theoretical en‐
gine speed calculated by the engine control unit. When the
engine is idling the engine control unit tries constantly to adjust
the actual engine speed so that it matches the specified value.
9. Evaluating measured value blocks, display groups 50...69 -Engine speed regulation- 71
Passat 1997 ➤
Display group 60 -Engine speed regulation- Adaptation of electronic throttle control system
• Ignition on, engine not running

60
xx % xx % x Text
1 2 3 4▾ Display zones Specification Evaluation
Adaptation status (ADP runs, ADP OK ---
ADP OK or ADP ERROR)
Learning step counter 0...8 ---
Throttle valve angle (potentiometer 2 -G188- ) 97...3 % ---
7) Adapting engine control unit to throttle valve control module ⇒ page 143 .
Notes on display group 60:
♦ Matching the throttle valve control module is performed with
ignition switched on.
♦ Engine control unit is adapted to throttle valve module when
selecting display group 60 under function 04 “Basic setting”.
This adaptation must always be carried out when another
throttle valve module (or another complete engine) or another
engine control unit has been fitted.
♦ If voltage supply has been interrupted (battery disconnected),
adaptation must also be carried out, ⇒ page 139 procedure
after interrupting the voltage supply.
♦ The counter counts up to 8 in display zone 3 during adaptation.
Display group 61 -Engine speed regulation- Electronic throttle control system
. Volkswagen AG
• Vehicle operation swa
gen AG does
olk not
yV gu
db ara
Read measured value block → ▾ Indicated on display ris
e nte
61 ho eo
aut ra
ss c
xxxx xx.xxx V xx.x% xxxxx
ce
e
rpm
nl
pt
du
an
itte
y li
erm
ab
Operating status xxxxx ⇒ page 71

ility
ot p
wit
, is n
Throttle valve angle (potentiometer 1 - 0...100 % ---

h re
G187- )
hole
spec
Voltage supply for engine control unit 12.0...15.0 V ⇒ page 58

es, in part or in w
t to the co

rrectness of i
l purpos
Note
nf
ercia
The engine control unit calculates the angle sender voltage value
rm
m
as a percent of 5 Volts and displays this percentage. (5 volt supply

atio
m
voltage equals 100 %).

o
n in
or c
thi
te
sd
iva
Display group 62 -Engine speed regulation- Electronic throttle control system

o
r
rp
cu
o

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
72
by c lksw
cted
Rep. Gr.01 - Self-diagnosis
agen
Prote AG.
Passat 1997 ➤

62
xx % xx % xx % xx %
Accelerator position sender 2 4...49 % ---
-G185
Accelerator position sender 1 -G79- 12...97 % ---
Note
The engine control unit calculates the potentiometer voltage value

as a percent of 5 Volts and displays this percentage. (5 volt supply
voltage equals 100 %).
Vehicles with cruise control system (CCS)

Display group 66 -Cruise control system

66
km/h xxxxxxx km/h xxxxxxx
x x
Switch position of CCS control 00000000 ⇒ page 74
switch agen AG. Volkswagen AG do
ksw es n
Specified road speed by (last value stored
Vol ---ot gua ---
by CCS) rised ran
te
tho eo
Brakes, clutch and CCS
s au switch position 10000000 r a ⇒ page 73
c
s
Road speed (actual) 0 km/h ---
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
Only the last 4 digits of the 8-digit display are described in the
t to the co
following tables.
Significance of the figures in the 4-digit display, display zone 2,

rrectness of i
brakes, clutch and CCS switches.

l purpos
1 1 1 1 Significance
Brake depressed (brake light switch)
nform
ercia
Brake depressed (brake pedal switch)

m
a
com
tio
Clutch depressed or brake depressed with automatic gearbox

n in
r
te o
Cruise control system enabled

thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
♦ Checking brake light and brake pedal switch ⇒ page 149
Co
Cop py
t. rig
gh ht
♦ Checking clutch pedal switch ⇒ page 149 yri
p by
co Vo
by lksw
cted agen
Prote AG.
9. Evaluating measured value blocks, display groups 50...69 -Engine speed regulation- 73
Passat 1997 ➤
wage e
♦ Cruise control system not enabled:
yV
olk⇒
s Electrical system; Rep.s no
t gu
Gr. 27 ise
d b ara
n r tee
ho
Significance of the figures sin
au the 4-digit display, display zone 4,
t or
ac
CCS control switches s
ce
e
nl
pt
du
an
1 1 0 0 Significance
itte
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erm
ab
CCS sliding switch at OFF (engaged only, not engaged = 1)
ility
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CCS sliding switch at OFF (not engaged)
wit
, is n
h re
SET button pressed
hole
spec
CCS sliding switch at RES
es, in part or in w
t to the co
rrectness of i
⇒ Electrical system; Repair group 27
⇒ Owner's Manual in vehicle
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
10 Evaluating measured value blocks, display groups 70...78 -Exhaust

emission reduction-
Display group 70 -Exhaust emission reduction- Activated charcoal filter system (tank vent system) diag‐
nosis
• Coolant temperature at least 60 °C

70
xxx % xx.x% Text
Result of diagnosis (Test ON / TVV OK ---
OFF or TVV OK / n.OK)
Lambda control deviation on TVV diagnosis -7...7 % ---

Activated charcoal filter system solenoid valve 1 duty cycle 0...100 % ---
AG. Volkswagen AG d
agen oes
ksw
Note by
Vol not
gu
d ara
ise nte
or
TVV means: ut Tank vent valve (activated charcoal filter system
h eo
a ra
solenoids valve 1). Diagnosis can only be introduced once per
s c en‐
gine start.
ce
e
nl
pt
du
an
itte
y li
erm

ab
ility
ot p
♦ Lambda control deviation in negative range: Activated char‐

wit
, is n
coal filter full

h re
hole
spec
♦ Lambda control deviation in positive range: Activated charcoal

es, in part or in w
filter empty
t to the co
Display group 77 -Exhaust emission reduction- Secondary air system bank 1 diagnosis
rrectness of i

l purpos

nform

ercia
77
m
at
om
xxxx x.x g/s x.x g/s Text

ion
c
rpm
in t
or
his
te
a
do
priv
Result of diagnosis (Test ON / Syst. OK ---

um
for
en
g
OFF, Syst. OK / n.OK, Abort)

n
t.
yi Co
op py
Secondary air system air mass 4.0…10.0 g/s ---
t. C rig
gh ht
yri by
Intake air mass 3.0…5.0 g/s ---
op Vo
by c lksw
cted agen
Prote
AG.
10. Evaluating measured value blocks, display groups 70...78 -Exhaust emission reduction- 75
Passat 1997 ➤
11 Evaluating measured value blocks,

display groups 90...95 -Enhanced
performance-
Camshaft timing control
Display group 90 -Enhanced performance- Exhaust camshaft

90
xxxx Text xx.x °CA
rpm
--- ---
Camshaft adjustment angle (actual) 0...22° CA ---
Variable valve timing operating status On / off ---
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Notes on displayorizones
se
d
2 and 3: nte
th eo
u ra
♦ The operating
ss a status and adjustment angle are displayed ac‐c
cording to engine speed or load.
ce
e
nl
pt
du
an
♦ Checking variable valve timing: ⇒ Rep. Gr. 15; Repairing

itte
y li
valve gear; Checking variable valve timing

erm
ab
ility
ot p
Display group 91 -Enhanced performance- Continuous variable valve timing, inlet camshaft
wit
, is n
h re
hole
spec
es, in part or in w

t to the co
91
xxxx xxx % xx.x °CA xx.x °CA
rrectness of i
rpm
l purpos
Actual inlet camshaft adjust‐ 0...52° CA ---

ment angle
nf
ercia
or
Specified inlet camshaft adjustment an‐ 0...52° CA ---

m
m
atio
gle
om
n in
c
Duty cycle 0...100% ---

or
thi
te
sd
a

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
Note on display zones 3 and 4:
t. rig
gh ht
pyri by
Vo
o
♦ Checking variable valve timing: ⇒ Rep. Gr. 15; Repairing
c by lksw
cted agen
valve gear; Checking variable valve timing Prote AG.
Display group 95 -Enhanced performance- Variable intake manifold


95
xxxx xx.x% xx.x°C Text
rpm

Passat 1997 ➤
Status of variable intake mani‐ SU-V ON ---

fold SU-V OFF
olkswagen AG
Engine load wage
n AG. V
do0...120
es n % ---
olks ot g
Engine speed ed
byV 650...6500 uararpm ---
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
The variable intake manifold can be activated via abrupt acceler‐
wit
, is n
ation at below 4000 rpm. If the actuator on the intake manifold
h re
does not carry out the changeover movement, check variable in‐
hole
spec
take manifold ⇒ page 122 .
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
11. Evaluating measured value blocks, display groups 90...95 -Enhanced performance- 77
Passat 1997 ➤
12 Evaluating measured value blocks, display groups 120...126 -Com‐

munication-
Display group 120 -Traction control system -TCS-

120
xxxx xxx Nm xxx Nm Text
rpm
Status TCS active / TCS ---
n.active
Actual engine load 0...150 Nm ---
Specified engine load 0...346 Nm ---

♦ The specification depends on the current driving status.
. Volkswag
AG en AG
agen does
ksw
Display group 122 -Gearbox yV
ol (automatic only) not
gu
db ara
• Vehicle operation rise nte
tho eo
s au ra
c
Read measured value block
s
→ ▾ Indicated on display
ce
le
122
un
pt
an
d
itte
xxxx xxx Nm xxx Nm Text

y li
erm
ab
rpm
ility
ot p

wit
is n
h re
Status Engine interv./no ---

ole,
spec
interv.
t to the co
Actual engine load 0...260 Nm ---

Specified gearbox torque 0...399 Nm ---
rrectne

ss o
cial p
Display group 125 -Communication -Data bus messages-

inform
mer

atio
om
n
c

i
or
n thi
e
125
t
sd
iva
o
r
Text Text Text

p
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
gh ht
Instrument cluster status
yri
Instrument cluster 1 ---
p by
o Vo
by c lksw
ABS status cted
ABS 1 ---
agen
Prote AG.
Gearbox status Gear. 1
Notes on display group 125:

♦ Specification = 1; the control units with active data bus are
displayed.
Display group 126 -Communication -Data bus messages-

Passat 1997 ➤

126
Text
Airbag status (1 / 0) Airbag 1 ---
Note
If 0 appears in display, an error exists in data bus operation.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
12. Evaluating measured value blocks, display groups 120...126 -Communication- 79

Passat 1997 ➤
24 – Mixture preparation - injection

1 Repairing injection system
1.1 Overview of fitting locations
1 - Lambda probe 1 bank 1 be‐

fore catalytic converter -G39- , lkswage es n
50 Nm d byV
o ot g
ua
ran
❑ Installation position on ir se tee
tho
or
vehicles with front- au ac
ss
wheel drive: in front ex‐
ce
e
nl
haust pipe, before cata‐
pt
du
an
lytic converter.
itte
y li
erm
ab
2 - Lambda probe 2 bank 1 af‐
ility
ot p
ter catalytic converter -G130- ,
wit
, is n
50 Nm
h re
hole
spec
❑ Installation position on
es, in part or in w
vehicles with front-
t to the co
wheel drive: behind cat‐
alytic converter
rrectness of i
3 - Hall sender -G40-
❑ For inlet camshaft.
l purpos
❑ Mark connector before

removing
nf
ercia
or
4 - Inlet camshaft control valve
m
m
atio
1 -N205-
om
n in
c

or
thi
te
sd

iva
o
r
removing
rp
cu
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m
f
en
ng
5 - Inlet camshaft control valve

t.
yi Co
op
1 -N318-
C py
t. rig
gh ht
yri
❑ For exhaust camshaft. p by
co Vo
by lksw
cted
agen
Prote AG.
removing
6 - Hall sender -G163-
❑ For exhaust camshaft.
removing
7 - Connector
❑ For engine control unit.
❑ Only disconnect or connect with ignition switched off.
❑ Release to pull off
8 - Engine control unit
(Motronic control unit -J220- )
❑ Location: in plenum chamber.
9 - 6-pin connector
❑ Black.
❑ Gold-plated contacts
❑ For Lambda probe 1 before catalytic converter -G39- and Lambda probe heater -Z19- .
80 Rep. Gr.24 - Mixture preparation - injection

Passat 1997 ➤
10 - 4-pin connector
❑ Brown
❑ Contacts 3 and 4 gold-plated
❑ For Lambda probe 2 after catalytic converter -G130- and Lambda probe heater -Z29- .
❑ Grey
❑ For engine speed sender -G28- .
❑ Brown
❑ For knock sensor 1 -G61- .
❑ Black.
❑ For knock sensor 2 -G66- .
14 - Vacuum unit
❑ For intake manifold change-over.
15 - Fuel pressure regulator
16 - Coolant temperature sender -G62-
❑ Blue.
❑ With coolant temperature gauge sender -G2-
❑ Before removing, release pressure
wage
n AGin
. Vocooling system
lkswagen AG
does if necessary.
ks not
Vol gu
17 - Engine speed sendere-G28-
db
y ara
nte
is
or eo
18 - Knock sensor 2 -G66-
au
th ra
ss c
❑ Fitting location: cylinder block intake side
ce
e
nl
pt
du
an
19 - Secondary air inlet valve -N112-

itte
y li
erm
ab
❑ Secondary air system: ⇒ Rep. Gr. 26; Secondary air system; Removing and installing parts of secondary
ility
ot p
air system .
wit
, is n
h re
20 - Variable intake manifold changeover valve -N156-

hole
spec

es, in part or in w
t to the co
21 - Injector ( -N30- ...N33, N83)

22 - Tensioning plate
rrectness of i
23 - Ignition coil with output stage ( -N70- , N127, N291, N292 and N323)
l purpos
❑ Remove using puller -T10095- .

❑ Checking ⇒ page 160 .
nform
ercia
24 - Knock sensor 1 -G61-

m
at
❑ Location: cylinder block exhaust side

om
ion
c
in t
r
25 - Secondary air pump motor -V101-

o
his
ate
do
priv
air system .
um
for
en
ng
t.
yi
26 - Air filter
Co
Cop py
t. rig
gh
27 - Activated charcoal filter solenoid valve 1 -N80-
ht
pyri by
Vo
co lksw
❑ Secured to air filter upper part.
by
cted agen
Prote AG.
❑ For activated charcoal filter system: ⇒ Rep. Gr. 20; Activated charcoal filter system .
28 - Air mass meter -G70- with intake air temperature sender -G42-
29 - Throttle valve control module -J338-
❑ Heated by coolant.
1. Repairing injection system 81

Passat 1997 ➤
❑ For secondary air pump relay -J299- .
1.2 General notes on injection

Repairing ignition: ⇒ Rep. Gr. 28
♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, read fault memory. Also
the vacuum hoses and connections must be checked (unme‐
tered air).
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
♦ Components marked with * are checked via self-diagnosis
⇒ page 8 , Reading and erasing fault memory.
♦ Components marked with ** can be checked
en AG. V
olkswagenusing
AG do final control
diagnosis ⇒ page 29 . olkswag es n
o V t gu
by a
♦ For trouble-free operation
ise
d
of electrical components, a voltage
ran
tee
or
of at least 11.5
au
thV is necessary. or
a
ss c
♦ Do not use sealants containing silicone. Particles of silicone
ce
le
un
drawn into the engine will not be burnt in the engine and dam‐
pt
an
d
itte
age the Lambda probe.

y li
rm
ab
pe
♦ Certain tests may lead to a fault being detected by the control ility
ot
unit and stored. Therefore, after completing all checks and re‐
wit
, is n
h re
pairs the fault memory must be read and if necessary erased
hole
⇒ page 8 , Reading and erasing fault memory, and readiness

spec
code must be generated ⇒ page 44 .

es, in part or in w
t to the co
Safety precautions ⇒ page 89 .

Rules for cleanliness ⇒ page 90 .
rrectness of i
Technical data ⇒ page 90 .

l purpos
Checking engine operating statuses ⇒ page 136 .

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
1.3 Removing and installing parts of the injection system
1 - Intake manifold
❑ Dismantling and assem‐
bling ⇒ page 85 .
❑ Removing and instal‐
ling: ⇒ Rep. Gr. 15; Re‐
moving and installing
cylinder head; Remov‐
ing and installing cylin‐
der head cover .
2 - Throttle valve module -
J338- *
3 - Rubber bush
❑ For intake manifold
4 - Connector
❑ Release to pull off
❑ Only disconnect or con‐
nect with ignition switch‐
ed off.
5 - Motronic control unit -J220-
*
❑ Location: in plenum
chamber.
❑ Checking voltage sup‐
ply ⇒ page 138 . . Volkswagen AG
gen AG does
❑ Procedure after inter‐ Volkswa not
rupting the voltageedsup‐
by gu
ara
ply ⇒ page 139horis nte
eo
ut ra
❑ Renewing ⇒ss apage 140 . c
ce
le
❑ Coding ⇒ page 141 .

un
pt
an
d
❑ If renewed, carry out ba‐

itte
y li
erm
sic setting ⇒ page 143 .

ab
ility
ot p
6 - 20 Nm
wit
is n
h re
ole,
7 - Vacuum connection from fuel pressure regulator

spec
8 - Vacuum connection for brake servo

t to the co
9 - Union for activated charcoal filter

❑ From activated charcoal filter solenoid valve 1 -N80- : ⇒ Rep. Gr. 20; Activated charcoal filter system .
rrectne
10 - Throttle valve module -J338- *

ss
11 - Coolant temperature sender -G62- *

o
cial p
f i
❑ Blue marking
nform
mer

atio
m
❑ With coolant temperature gauge sender -G2-

o
n
c
i
or
❑ Before removing, release pressure in cooling system if necessary.

thi
te
sd
va

i
o
pr
cum
r
fo
❑ Wiring chamber 3 and wiring chamber 4 for G62

en
ng
t.
yi Co
❑ Gold-plated contacts Cop py
t. rig
gh ht
yri
12 - Retaining clip p by
co Vo
by lksw
cted
❑ Check for secure seating.
agen
Prote AG.

Passat 1997 ➤
AG. Volkswagen
n AG do
wage es n
olks ot g
13 - Thermostat housing ed
by
V ua
ran
ris
❑ Location ⇒ page tho 80 , overview - engine compartment. tee o
au ra
c
ss
14 - Crankcase breather valve
ce
e
nl
pt
du
15 - Air mass meter -G70- * with intake air temperature sender -G42- *
an
itte
y li
❑ Checking G70 ⇒ page 96 .
erm
ab
ility
ot p
❑ Checking G42 ⇒ page 108 .
wit
, is n
❑ Gold-plated contacts on sensor and connector.
h re
hole
spec
16 - Air duct
es, in part or in w
t to the co
17 - Engine speed sender -G28- *
❑ Location ⇒ page 80 , overview - engine compartment.
rrectness of i
l purpos
18 - Lambda probe 2 bank 1 after catalytic converter -G130- *, 50 Nm

❑ Fitting location: behind catalytic converter.
nf
ercia
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe
orm
body.
m
atio
m
❑ Remove and install with 3337

o
n in
or c
❑ With 4-pin connector.
thi
te
sd
iva
❑ Probe heating voltage supply via fuel pump relay -J17- .
o
r
rp
cu
o
❑ Checking Lambda probe heating for Lambda probe after catalytic converter ⇒ page 93 . m
f
en
ng
t.
yi Co
❑ Checking Lambda probe and Lambda control after catalytic converter ⇒ page 131 . Cop py
t. rig
gh ht
yri
19 - Lambda probe 1 bank 1 before catalytic converter -G39- *, 50 Nm p by
co Vo
by lksw
cted
❑ Fitting location: in front exhaust pipe, before catalytic converter.
agen
Prote AG.
❑ Grease only the threads with “G 052 112 A3”; “G 052 112 A3” must not get into the slots on the probe
body.
❑ Remove and install with 3337
❑ With 6-pin connector.
❑ Probe heating voltage supply via fuel pump relay -J17- .
❑ Checking Lambda probe heating for Lambda probe before catalytic converter ⇒ page 91 .
❑ Checking Lambda probe and Lambda control before catalytic converter ⇒ page 128 .
❑ Checking Lambda probe ageing, Lambda probe 1 ⇒ page 134 .
20 - Intake hose
❑ To secondary air pump motor -V101- : ⇒ Rep. Gr. 26; Secondary air system; Removing and installing
parts of secondary air system .
21 - Air filter
❑ Dismantling and assembling ⇒ page 88 .
22 - Activated charcoal filter solenoid valve 1 -N80-
23 - To vacuum connection ⇒ Item 7 (page 83)
24 - Fuel rail
25 - Non-return valve
❑ Black side of valve faces to fuel pressure regulator junction piece
26 - To vacuum reservoir
❑ Reservoir fitting location is beneath left wheel housing cover on A-pillar.
27 - To combination valve
air system .

lkswage es n
o ot g
byV ua
d ran
ir se te
o
auth Passate o1997
ra ➤
c
Motronic injection
ss and ignition system (5-cyl. 4-valve) - Edition 11.2009
ce
e
nl
pt
du
an
28 - To vacuum positioning element
itte
y li
erm
ab
29 - Connector
ility
ot p
wit
❑ Black, 2-pin.
, is n
h re
hole
30 - Intake manifold changeover valve -N156- */**
spec
es, in part or in w
t to the co
❑ Checking intake manifold change-over ⇒ page 122
31 - Secondary air inlet valve -N112- */**
rrectness of i
l purpos
air system .
nform
ercia
32 - Wiring harness
m
at
❑ With connectors: 10-pin to injectors and 8-pin to ignition coils.
om
ion
c
in t
r
33 - To variable intake manifold changeover valve -N156-

o
his
ate
do
riv
34 - Vacuum unit
p
cum
or

f
en
ng
t.
yi Co
❑ Checking ⇒ page 122 . t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
1.4 Dismantling and assembling intake manifold
AG.
1 - Intake manifold
❑ Removing and instal‐
ling: ⇒ Rep. Gr. 15; Re‐
moving and installing
cylinder head; Remov‐
ing and installing cylin‐
der head cover .
2 - Seal
❑ Renew.
3 - Bearing cap
change-over barrel
4 - 10 Nm
5 - 23 Nm
6 - Rubber bush
❑ For intake manifold sup‐
port.
7 - Vacuum connection
change-over, fuel pres‐
sure regulator and sec‐
ondary air inlet valve
❑ For brake servo
❑ From connecting hose
junction for crankcase
breather/activated char‐
coal filter system sole‐
noid valve 1.

Passat 1997 ➤
10 - Gasket
11 - Throttle valve module -J338- *
❑ If renewed, adapt engine control unit ⇒ page 143 .
❑ Gold-plated connector contacts.
❑ Heated by coolant.
12 - Earth wire
13 - 10 Nm
14 - Vacuum unit
15 - To intake manifold changeover valve -N156-
16 - Bracket
❑ For 8-pin and 10-pin connectors.
17 - Positioning lever
❑ For change-over barrel.
AG. Volkswagen AG d
18 - Change-over barrel agen oes
olksw not
byV gu
ara
d
19 - Gasket orise nte
h eo
❑ Note installation position aut ra
ss c
❑ Renew if damaged.
ce
e
nl
pt
du
an
20 - Dowel sleeve
itte
y li
erm
ab
❑ To secure intake manifold.
ility
ot p
❑ To locate seal.
wit
, is n
h re
hole
21 - 13 Nm
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
Motronic injection and ignition system
AG. Volksw(5-cyl.
agenA 4-valve) - Edition 11.2009
n G do
wage es n
Volks ot g
1.5 Dismantling and assembling fuel rail ris
ed
by ua
ran
tee
tho
or
au ac
ss
1 - To intake hose
ce
le
un
pt
❑ For air shrouding of in‐
an
d
itte
y li
jectors
rm
ab
pe
ility
2 - Seal
ot
wit
, is n
❑ Renew.
h re
hole
spec
3 - Injector ( -N30- ...N33 and es, in part or in w
N83) *
t to the co
❑ Air shrouded.
rrectness of i
4 - Retaining clip
l purpos
❑ Check for secure seat‐

ing.
nform
ercia
5 - Supply line connection

m
a
com
ti
6 - Return line connection
on in
r
te o
thi
7 - 10 Nm
s
iva
do
r
rp
c
8 - Retaining clip
um
fo
en
g
❑ Check for secure seat‐

n
t.
yi Co
op
ing. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted
❑ To non-return valve/in‐
agen
Prote AG.
take manifold junction
piece
10 - Fuel pressure regulator
❑ Checking ⇒ page 119 ,
checking fuel pressure
regulator and holding
pressure
11 - Fuel rail

Passat 1997 ➤
1.6 Dismantling and assemblinglkswair

agenfilter
AG. Volkswagen AG d
oes
n o ot g
yV ua
edb ran
ris tee
1 - Air mass meter -G70- * with aut
ho or
ac
intake air temperature sender - ss
G42- *
ce
e
nl
pt
du
an
❑ Checking G70
itte
y li
⇒ page 96 . erm
ab
ility
ot p
❑ Checking G42
wit
, is n
⇒ page 108 .
h re
hole
❑ Gold-plated contacts on
spec
sensor and connector.
es, in part or in w
t to the co
2 - Intake hose
❑ From air filter to throttle
rrectness of i
valve module
❑ Ensure that spring-type
l purpos
clips are securely seat‐

ed
nform
ercia
3 - Connector
m
at
❑ Black, 2-pin.
om
ion
c
❑ For heater element -
in t
or
his
e
N79-
at
do
riv
❑ With engine running,

p
cum
or
check voltage supply for

f
en
ng
t.
yi
heating resistor be‐
Co
op py
tween contacts 1 and 2.
t. C rig
gh ht
yri
Specification: min. 11.5 p by
co Vo
V.
by lksw
cted agen
Prote AG.
4 - Heater element -N79-
❑ For crankcase ventila‐
tion.
❑ Heater element -N79-
for certain countries on‐
ly.
❑ Checking ⇒ page 90 ,
⇒ page 90 .
❑ Resistance at ambient
temperature (approx. 25
°C), specification: 7…12 Ω
5 - Intake hose
❑ For crankcase ventilation.
❑ From crankcase breather valve to cylinder head cover.
❑ Press together at front to release.
6 - Vacuum hose
❑ For crankcase ventilation.
❑ To intake manifold
7 - 6 Nm
8 - Air filter upper part
9 - Intake hose
❑ To secondary air pump motor -V101- : ⇒ Rep. Gr. 26; Secondary air system; Removing and installing
parts of secondary air system .

Passat 1997 ➤
10 - Air duct
11 - Filter element
12 - Rubber grommet
❑ For securing on body.
13 - Air filter lower part
14 - 10 Nm
15 - Seal
❑ Renew if damaged.
16 - Connector
❑ Black, 5-pin.

♦ For safety reasons, fuse No. 28 must be removed from the
fuse holder before opening the fuel system. Otherwise the fuel
pump can be activated by the driver door contact switch.
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.
To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:
G. Volkswagen AG d
♦ Do not touch or disconnect ignition cables when thelksengine
wage
n A is oes
not
running or being turned at starter speed. db
yV
o gu
ara
rise nte
♦ Switch off ignition before connecting or disconnecting
utho injection eo
ra
and ignition system wiring as well as test
ss a instrument cables. c
ce
e
nl

pt
du
an
during a road test:

itte
y li
erm
ab

ility
ot p

wit
, is n
h re

hole
spec

es, in part or in w
t to the co

♦ If the engine is to be turned at starter speed without starting:
rrectness of i
– Pull fuse no. 29 and 32 out of fuse holder.

l purpos
Note
nform
mercia
at
Removing fuse 29 interrupts the voltage supply to the ignition

om
io
coils, and removing fuse 32 interrupts the voltage supply to the

n
c
in t
or
injectors.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
Heater element for crankcase breather N79

At ambient temperature (approx. 25°C), heater element for crank‐
case breather has a resistance of: specification: 7…12 Ω
To check voltage supply:
– Pull off 2-pin connector and measure at connector contacts 1
+2 with ignition switched on. Specification: at least 11.5 V
If no voltage is present:
– Check line connection from contact 1 to fuel pump relay -J17-
and from contact 2 to earth using current flow diagram. ⇒ Cur‐
1.8 Rules for cleanliness

When working on the fuel supply and injection systems, pay care‐
ful attention to the following “5 rules” for cleanliness:
♦ Thoroughly clean all unions and adjacent areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their
n packing
AG. Volksw(e.g.
agen Ain
G do
tool boxes etc.). wage es n
olks o V t gu
by ara
♦ When system is open: do notriwork
se
d
with compressed air if this nte
can be avoided. Do not move
autho vehicle unless absolutely nec‐ eo
ra
essary. ss c
ce
e
nl
pt
1.9 Technical data

du
an
itte
y li
erm
ab
Engine codes AZX

ility
ot p
wit
, is n
Idling check
h re
hole
Idling speed9) rpm 650...7508)

spec
es, in part or in w
Engine control unit10)

t to the co
System designation Motronic ME7.1

Part number ⇒ Parts catalogue
rrectness of i
Governed speed rpm from approx. 6500

l purpos
nf
ercia
8) Current values: ⇒ Exhaust emissions test

orm
m
9) Not adjustable
atio
om
n in
10) Renewing engine control unit ⇒ page 138 .

or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
2 Checking components
2.1 Checking Lambda probe heating for

Lambda probes before catalytic convert‐
er
Only gold-plated contacts may be used when repairing Lambda
probe connector contacts.
♦ Test box -V.A.G 1598/31-
Test prerequisites
• Fuse 34 must be OK.
• Fuel pump relay must be OK.
Test sequence for Lambda probe 1 bank 1 olkswage es n
ot g
byV ua
– Connect fault reader -V.A.G 1551- (V.A.G ir se1552). Start engine
d ran
tee
and select “Address word” 01 of engineuth control unit. (Connect
o
or
fault reader and select engine control
ss unit ⇒ page 4 )
a ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
Select function XX
ot p
wit
is n

h re
ole,
and confirm entry with Q key. spec

t to the co
Reading measured value block

rrectne

ss
confirm entry with Q keys.

o
cial p
f inform

mer
atio
om
Read measured value block 41 ->

n
c
1 2 3 4
or
n thi
te
sd
a
– Check specification for Lambda probe heating in display zone

iv
o
pr
2.
um
r
fo
en
ng
t.
yi Co
op py
Display zones t. C rig
gh ht
yri by
1 2 3 4
cop Vo
by lksw
cted agen
Display group 41: Lambda probe heating before and after catalytic converter Prote AG.
Readout --- Heat. bef. cat. ON / --- Heat. af. cat. ON / heat.
heat. bef. cat. OFF af. cat. OFF
2. Checking components 91
Passat 1997 ➤
Display zones
Display --- Lambda probe heating --- Lambda probe heating
shows before catalytic con‐ after catalytic convert‐
verter ON er ON
or or
Lambda probe heating Lambda probe heating
before catalytic con‐ after catalytic convert‐
verter OFF er OFF
Specifi‐ --- Heat. bef. cat. ON --- ---
cation Heat. bef. cat. OFF
(occasionally alternat‐
ing)
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
Lambda probe heating may be switched ton horis
or off depending on nte
eo
the engine's operating status, i.e. the displays
s au in display zone 2 ra
c
may show either Htg.b(a)C.ON or alternatingly
s Htg.b(a)C.ON/
ce
e
Htg.b(a)C.OFF.
nl
pt
du
an
itte
y li
erm
ab
If the specifications are not obtained
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Disconnect 6-pin connector (black) -1- to Lambda probe be‐
rrectness of i
fore catalytic converter -G39- .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
– Set multimeter to resistance measurement and check resist‐ copy Vo
by lksw
ance of probe heating at connector to Lambda probe between cted agen
Prote AG.
contacts 3+4; specification: 2.5...10.0 Ω
If it is determined that probe heating has an open circuit:
– Renew Lambda probe before catalytic converter -G39- .
If Lambda probe is renewed, learnt values in engine control unit
must be erased ⇒ page 142
If probe heating has continuity:
Checking voltage supply

Passat 1997 ➤
– Connect multimeter with auxiliary cables from -V.A.G 1594- to

measure voltage at contacts 3+4 (connector to engine control
unit).
– Start engine and run at idling speed.
– Measure voltage supply and observe display group 42, display
zone 2.
• Display Heat.bC.ON: specification: 11.0...14.5 V.
• Display Heat.bC.ON/heat.bC.OFF (alternatingly): specifica‐
tion: Fluctuating between 0.0...12.0 V.

– Check line between test box and 6-pin connector for open cir‐
cuit referring to current flow diagram. Contact 4+socket 5 line
resistance: Max. 1.5 Ω
If specification is attained: olksw
n AG. V agen AG
wage does
– Check line Vbetweenolks 6-pin connector contact
not 3 and fuel pump
g
relay -J17-d by
for open circuit using current flowuadiagram.
ran Cable
ise
resistance:
thor max. 1.5 Ω. tee
o
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
2.2 Checking Lambda probe heating for

h re
hole
spec
Lambda probes after catalytic converter

es, in part or in w
t to the co

rrectness of i

l purpos
♦ Test box -V.A.G 1598/31-

nform
ercia

m
a
com
ti

on in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Passat 1997 ➤
AG. Volkswagen AG d
Test prerequisites agen oes
o lksw not
V gu
by ara
• Fuse 34 must be OK. rised
nte
ho eo
ut
• The battery voltage
ss a must be at least 11.5 V. ra
c
ce
le

un
pt
an
d
itte
y li
Test sequence for Lambda probe 2 bank 1
erm
ab
ility
ot p
– Connect fault reader -V.A.G 1551- (V.A.G 1552). Start engine
wit
is n
and select “Address word” 01 of engine control unit. (Connect
h re
fault reader and select engine control unit ⇒ page 4 )
ole,
spec
t to the co
Select function XX
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

t
sd
iva

o
pr
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
Read measured value block 41 gh -> ht
pyri by
1 2 3 o 4 Vo
by c lksw
cted agen
Prote
– Check specification for Lambda probe heating in display zone
AG.
4.
Display zones
1 2 3 4
Display group 41: Lambda probe heating before and after catalytic converter
Readout --- Heat. bef. cat. ON / --- Heat. af. cat. ON / heat.
heat. bef. cat. OFF af. cat. OFF
Display --- Lambda probe heating --- Lambda probe heating
shows before catalytic con‐ after catalytic convert‐
verter ON er ON
or or
Lambda probe heating Lambda probe heating
before catalytic con‐ after catalytic convert‐
verter OFF er OFF
Specifi‐ --- --- --- Heat. aft. cat. ON
cation Heat. aft. cat. OFF
(occasionally alternat‐
ing)
Note
Lambda probe heating may be switched on or off depending on

the engine's operating status, i.e. the displays in display zone 4
may show either Htg.b(a)C.ON or alternatingly Htg.b(a)C.ON/
Htg.b(a)C.OFF.


Passat 1997 ➤

– Disconnect 4-pin connector (brown) -2- to Lambda probe after
catalytic converter -G130- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Set multimeter to resistance measurement and check resist‐

un
pt
ance of probe heating at connector to Lambda probe between
an
d
itte
y li
contacts 1+2; specification: 8.0...20.0 Ω
erm
ab
ility
ot p
If it is determined that probe heating has an open circuit:
wit
is n
h re
– Renew Lambda probe after catalytic converter -G130- .
ole,
spec
t to the co
must be erased ⇒ page 142
If probe heating has continuity:
rrectne
ss o
cial p
f
– Connect multimeter using auxiliary cables from -V.A.G 1594-
inform
to measure voltage at contacts 1+2 (connector to engine
mer
control unit).
atio
om
n
c
i
or
n thi
te
– Measure voltage supply and observe display group 41, display

sd
iva
o
r
zone 4.
p
cum
r
fo
en
ng
• Display Heat.aC.ON: specification: 11.0...14.5 V.

t.
yi Co
Cop py
.
• Display Heat.aC.ON/heat.aC.OFF (alternatingly): specifica‐
t rig
gh ht
yri by
tion: Fluctuating between 0.0...12.0 V. cop Vo
by lksw
cted agen
Prote
AG.

Passat 1997 ➤
– Check line between test box and 4-pin connector for open cir‐
cuit referring to current flow diagram. Contact 2+socket 63
Line resistance: Max. 1.5 Ω
If specification is attained:
2.3 Checking air mass meter
Note
Only gold-plated contacts may be used when repairing contacts

in air mass meter connector.

AG. Volkswagen AG d
♦ Test box -V.A.G 1598/31- agen oes
olksw not
y V gu
b ara
♦ Hand multimeter -V.A.G 1526- or multimeter rise -V.A.G 1715-
d
nte
tho eo
♦ Auxiliary measuring set -V.A.G 1594-ss au ra
c
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
Test prerequisites
wage
• Fuse 34 must be OK. olks es n
ot g
byV ua
ed ran
• The battery voltage must be at least 11.5 V. horis tee
ut or
a ac
• Fuel pump relay must be OK. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
switched off.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
04, display zone 3.
rrectness of i
Test sequence:
l purpos

nf
ercia
or
m
m
atio
om
n in
c

or
thi
Select function XX
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
Reading measured value block by
cted agen
Prote AG.

1 2 3 4
– Check intake air mass in display zone 4.
Display zones
1 2 3 4
Display group 2: Load detection
Readout xxxx rpm xxx.x % xx.xx ms xxx.x g/s
Display Engine speed Engine load Injection period Intake air mass
shows (in steps of 40 rpm)
Range 0...6800 rpm 0.0...100.0 % 0.00...20.00 ms 0.0...140.0 g/s
Specifi‐ 650...750 rpm --- --- 1.0...25.0 g/s
cation
--- --- --- If the specification is
not attained
⇒ page 98 , evaluat‐
ing display group 2
– If specification is not attained or a fault regarding air mass

meter is still present in fault memory, check voltage supply
⇒ page 98 and signal and earth line of air mass meter
⇒ page 99 .
Passat 1997 ➤
Evaluating display group 2, display zone 4 - Air mass drawn in
Less than 1.0 g/s ♦ Large amount of unmetered air between – Check intake system for leaks (unme‐
intake manifold and air mass meter tered air) ⇒ page 124
More than 25.0 g/s ♦ Engine loaded due to ancillaries – Eliminate load (air conditioner, power-
assisted steering etc.)

♦ The air mass measured by the air mass meter is displayed.
♦ The substitute value in g/s from throttle valve potentiometer
will be displayed if the engine control unit detects a fault on the
air mass meter.
Checking voltage supply for air mass meter
– Pull 5-pin connector off air mass meter -G70- with intake air
temperature sender -G42- -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Connect multimeter to measure voltage at connector contact

hole
2 and engine earth.

spec
es, in part or in w
t to the co
– Start engine and run at idling speed. Specification: 11.0...15.0

V
rrectness of i

l purpos

nform
ercia

m
at
om
If the voltage supply and lines are OK:

ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
Motronic
agen AG. Vinjection
olkswagen and
AG doignition system (5-cyl. 4-valve) - Edition 11.2009
w es n
olks ot g
yV ua
– Connect multimeter ris
ed to measure
b
voltage at connector contact
ran
tee
4 and engine uearth.
tho or
a ac
ss
– Switch on ignition. Specification: at least 4.5 V
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Checking signal and earth lines ⇒ page 99 .
, is n
h re
hole
Checking signal and earth lines for air mass meter
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
– Check lines between test box and 5-pin connector for open
by lksw
cted agen
Prote
circuit referring to current flow diagram.
AG.
Contact 5+ socket 29
• Cable resistance: max. 1.5 Ω.
– Additionally check all lines for short-circuit to one another.
• Specification: ∞ Ω.
– Additionally check lines for short circuit to battery positive or
earth.
– Renew air mass meter -G70- ⇒ Item 15 (page 84) ,
memory.
2.4 Checking throttle valve control module

Components of throttle valve control module -J338- : Throttle
valve drive -G186- , angle sender 1 for throttle valve drive -G187-
and angle sender 2 for throttle valve drive -G188- .
Note
If throttle valve module is renewed, new control module must be

adapted to engine control unit under all circumstances
⇒ page 143 .
Passat 1997 ➤
Special tools, workshop equipment, test and measuring equip‐

ment and auxiliary items required
♦ Test box -V.A.G 1598/31-
wage
♦ Current flow diagram olks es n
ot g
byV ua
ed ran
Test prerequisites horis tee
ut or
a ac
• Throttle valve notssdamaged or dirty.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
04, display zone 3.
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Only gold-plated contacts may be used when repairing contacts
in throttle valve module connector.
rrectness of i
l purpos

nform
ercia
⇒ page 4 )
m
at
om
io

n
c
in t
Select function XX
or
his
ate

do
priv

um
for
en
ng
t.
yi
Co
Cop py Reading measured value block
t. rig
gh ht
pyri by
Vo Input display group number XXX
co lksw
by
cted
agen
Prote AG.
– Check throttle valve angle of sender 1 -G187- at idling speed
stop in display zone 1.
– Check throttle valve angle of sender 2 -G188- at idling speed
stop in display zone 2.
Display zones
1 2 3 4
Display group 62: Engine speed regulation, electronic throttle control
Readout xxx % xxx % xxx % xxx %
Display Throttle valve drive an‐ Throttle valve drive an‐ Accelerator Accelerator
shows gle gle position sender 1 - position sender 2 -
sender 1 for electric sender 2 for electric G79- G185-
throttle -G187- throttle -G188-
Range 0...100 % 0...100 % 0...100 % 0...100 %
Specifi‐ 3...93 % 97...3 % 12...97 % 4...49 %
cation
If the specifications are not obtained --- ---
⇒ page 101 , continued

Passat 1997 ➤
– Slowly depress accelerator down to full throttle position and

observe the angle display in display zones 1 and 2:
The percent figures in display zone 1 must rise evenly. The tol‐
erance range of 3…93% is not covered completely.
The percentage figure in display zone 2 must decrease evenly.
The tolerance range of 97…3% is not covered completely.
Note
♦ The reason why the display in display zone 1 increases and

the display in display zone 2 decreases is because the poten‐
tiometers (angle senders) in the throttle valve control module
run in opposite directions.
♦ This means that the voltage tap of one angle sender moves
towards 5 V. (The more the throttle valve is opened, the higher
the voltage; percentage figure increases).
♦ Voltage tap of angle sender 2 decreases from 5 V towards 0
V. (The more the throttle valve is opened, the lower the voltage
becomes; percentage figure decreases).
If the specifications are attained:

. Volkswagen AG
entry with Q button. swa
gen AG does
olk not
yV gu
– Switch off ignition. edb ara
nte
ris
tho eo
Continuation au ra
c
ss
ce
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
wit
, is n

h re
hole
spec
– Pull 6-pin connector from throttle valve module -arrow-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
– Measure resistance of throttle valve drive between contacts 3

+ 5; specification: 1.0...5.0 Ω.
If the specification is not attained:
– Renew throttle valve module -J338- ⇒ Item 2 (page 83) .
memory.
– Adapt engine control unit to throttle valve module
⇒ page 143 .
– Check voltage supply of throttle valve module and lines to
control unit ⇒ page 102 .
– Checking accelerator position sender: ⇒ Rep. Gr. 20; Elec‐
tronic engine output control (electronic throttle control); Check‐
ing accelerator position sender
If the voltage supply and lines are OK:
Checking voltage supply and wiring to control unit
– Pull 6-pin connector from throttle valve module -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Connect multimeter to measure voltage at connector contacts

erm
ab
2 + 6.
ility
ot p
wit

, is n
h re
hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Connect the multimeter to measure voltage to contact 2 of the

connector and earth.

– Check lines between test box and connector for open circuit
using current flow diagram:
swage es n
Contact 4+ socket 84 byV
olk ot g
ua
d ran
ir se
Contact 5+ socket 118 tho tee
or
au ac
Contact 6+ socket 91 ss
ce
e
nl
pt
du

an
itte
y li
erm
ab
– Additionally check wires for short to one another.

ility
ot p
wit
, is n
h re
hole
– Additionally check lines for short circuit to battery positive or

spec
earth.
es, in part or in w
t to the co
If no fault in lines is detected:
rrectness of i
– Check voltage supply of engine control unit ⇒ page 138 .

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
2.5 Checking coolant temperature sender
Note
AG. Volkswagen AG d
agen oes
olksw not
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The engine control isedunit will use a substitute value to start
b arthe
an en‐
gine (starting temperature
thor
substitute value) as soon as a fault
tee
oris
stored in thessfault memory, which affects the coolant temperature
au ac
sender -G62- . The temperature then rises according to a model
ce
e
nl
stored in the engine control unit. When the engine has reached
pt
du
an
normal operating temperature, a fixed substitute value will be dis‐
itte
y li
erm
played after a certain period. This fixed substitute value is in turn
ab
ility
dependent upon the intake air temperature.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Test box -V.A.G 1598/31-
rrectness of i
l purpos

nf
ercia
orm
m
Test prerequisite
atio
om
n in
c
• Engine must be cold.

or
thi
te
sd
a
Test sequence:
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note . Cop py
rig
ht ht
rig by
py
Only gold-plated contacts may be used when repairing contacts co Vo
by lksw
3 and 4 in coolant temperature sender connector.
cted agen
Prote AG.

⇒ page 4 )
Select function XX

Indicated on display: Reading measured value block

Indicated on display: (1…4 = display zones) Read measured value block 4 ->
1 2 3 4
– Read off coolant temperature value in display zone 3.

Display zones
1 2 3 4
Display group 4: General engine data
Readout xxxx rpm xx.xxx V xxx.x °C xxx.x °C
Display Engine speed Voltage supply for en‐ Coolant temperature Intake air temperature
shows (in steps of 40 rpm) gine control unit
Range 0...6800 rpm 0.000...16.500 V -40.0...140.0°C -40.0...140.0°C

Passat 1997 ➤
Display zones
Specifi‐ 0 rpm 12.000...14.500 V Approx. ambient tem‐ ---
cation perature11)
--- --- If the specification is ---
not attained
⇒ page 105 ,
evaluating display
group 4
11) If a temperature is displayed which deviates greatly from the ambient tem‐
perature of the sender, check sender lines for transfer resistance or open circuit.
– Start engine and run at idling speed. The temperature value

must increase uniformly
– Switch off ignition. . Volkswagen AG
gen AG does
swa
– Renew coolant temperature sender -G62- by
Vwith
olk coolant tem‐ not
gu
perature display sender -G2- ⇒ Itemri11
se (page 83) .
d ara
nte
tho eo
s au ra
c
s
Note
ce
le
un
pt
an
d
itte
y li
Temperature increases in steps of 1.0°C.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
memory.
t to the co
Evaluating display group 4, display zone 3 - Coolant temperature
Display group: 4
Display zone: 3 Possible cause of fault Fault remedy rrectne
approx. -40.0 °C ♦ Open circuit or short-circuit to positive – Continuation ⇒ page 105

ss o
cial p
f i
approx. 140.0 °C ♦ Short to earth – Continuation ⇒ page 106

nform
mer
atio
om
n
c
i
or
n thi
e
Continuation of check when display reads approx. -40.0°C:

t
sd
iva
o
pr
– Pull 4-pin connector off coolant temperature sender -G62- with

um
r
fo
en
coolant temperature display sender -G2- -arrow-.

ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Bridge connector contacts 3+4 with auxiliary cables from -

V.A.G 1594- and observe display.
If display jumps to approx. 140.0°C: AG. Volkswagen AG d
agen oes
lksw not
– Press → button. byV
o gu
ara
ed
ris nte
ut
ho eo
ra
entry with Q button. ss a c
ce
e
nl
pt
du
an
itte
y li
– Renew coolant temperature sender -G62- with coolant tem‐
erm
ab
ility
perature display sender -G2- ⇒ Item 11 (page 83) .
ot p
wit
, is n
If display remains at approx. -40.0°C:
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Check lines according to current flow diagram ⇒ page 106 .

Continuation of check when display reads approx. 140.0.0°C:
nform
mercia
at
om
io
n
c
in t
or
his
If display jumps to approx. -40.0.0°C:
ate
do
priv
c
um
for
en
ng
t.
yi
Co
Cop py
entry with Q button. ht. rig
rig ht
py by
o Vo
by c lksw
cted agen
Prote AG.
memory.
If display remains at approx. 140.0.0°C:
Checking lines


AG. Volkswagen AG d
agen oes
olksw not
by
V guPassat 1997 ➤
d ara
e nte
Motronic injectionhoris
and ignition system (5-cyl. 4-valve) - Edition
e o 11.2009
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
Contact 4 + socket 108
m
atio
om
n in
c
Contact 3 + socket 93
or
thi
te
sd
a

iv
o
r
rp
cu
o
m
– Check line between test box and 4-pin connector contact 3 to
f
en
ng
t.
line contact 4 and to vehicle earth using current flow diagram.
yi Co
Cop py
t. rig
Contact 4+ socket 93 gh ht
pyri by
Vo
o
by c lksw
Contact 3+ vehicle earth Prote
cted AG.
agen
• Specification: ∞Ω
– Additionally check both lines for short-circuit to battery posi‐
tive. Specification: ∞Ω
– Measure resistance at contact C (signal) and D (earth) on

coolant temperature sender -G62- .
Area A shows resistance values for temperature range 0…50°C

and area B the values for temperature range 50…100°C.
Examples:
♦ 30°C corresponds to a resistance of 1500…2000 Ω
♦ 80°C correspond to a resistance of 275…375 Ω.
memory.
If there is no fault in the lines and the resistance values are OK:

Passat 1997 ➤
2.6 Checking intake air temperature sender
Note
Intake air temperature sender -G42- is part of air mass meter -

G70- and cannot be renewed individually.

V.A.G 1552- with cable -V.A.G 1551/3- . Volkswagen AG
gen AG does
swa
♦ Test box -V.A.G 1598/31- y Volk not
gu
edb ara
is nte
♦ Hand multimeter -V.A.G 1526- or multimeter -V.A.G
hor 1715- eo
aut ra
♦ Auxiliary measuring set -V.A.G 1594- ss c
ce
le
un
pt
an
d
itte
y li
erm
♦ Spring-type clip pliers -V.A.G 1921-
ab
ility
ot p
♦ Chilling spray (commercially available)
wit
is n
h re
ole,
Test procedure
spec
t to the co
Note
rrectne
Only gold-plated contacts may be used when repairing the con‐
tacts in intake air temperature sender connector.
ss o
cial p
f in
form
mer
atio
⇒ page 4 )
om
n
c
i
or
n
thi
e

t
sd
a
Select function XX
iv
o
pr
cum
r
fo
– Press keys 0 and 8 for function “Read measured value block” en

ng
t.
yi
Co
Cop py
t. rig
gh
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1 2 3 4
– Read off intake air temperature value in display zone 4.

Display zones
1 2 3 4
Display group 4: General engine data
Readout xxxx rpm xx.xxx V xxx.x °C xxx.x °C
Display Engine speed Voltage supply for en‐ Coolant temperature Intake air temperature
shows (in steps of 40 rpm) gine control unit
Range 0...6800 rpm 0.000...16.500 V -40.0...140.0°C -40.0...140.0°C
Specifi‐ 0 rpm 12.000...14.500 V --- Approx. ambient tem‐
cation perature12)

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
autho
Passat 1997 ➤
eo
ra
ss c
ce
le
un
pt
an
d
Display zones
itte
y li
rm
ab
--- --- --- If the specification is
pe
ility
not attained
ot
wit
, is n
⇒ page 109 , evaluat‐
h re
hole
ing display group 4
spec
es, in part or in w
t to the co
12) If a temperature is displayed which is below the ambient temperature of the
sender, first check sender lines for transfer resistance. Note when doing this that
rrectness of i
sender may become heated whilst stationary, e.g. due to radiated heat.
l purpos
Evaluating display group 4, display zone 4 - Intake air tempera‐
ture
nform
ercia
Display group: 4
m
a
Display zone: 4 Possible cause of fault Fault remedy
com
tion in
approx. -40.0 °C ♦ Open circuit or short-circuit to positive – Continuation ⇒ page 109
r
te o
thi
s
iva
do
approx. 140.0 °C ♦ Short to earth – Continuation ⇒ page 110
r
rp
cum
fo
en
ng
t.
yi
Approx. ambient ♦ Signal occasionally interrupted – Checking sender ⇒ page 109 ,
Co
op py
temperature continue with ambient tempera‐
t. C rig
gh ht
ture
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Continuation of check when display = ambient temperature:

– Remove intake hose between air mass meter and throttle
valve control module.
– Note intake air temperature value in display zone 4.
– Spray sender -arrow- with commercial chilling agent whilst ob‐
serving the temperature value. The temperature value must
decrease.
Continuation of check when display reads approx. -40.0°C:

Passat 1997 ➤
– Bridge connector contacts 1+3 using auxiliary cables from -

V.A.G 1594- and observe display.
If display jumps to approx. 140.0°C:
– Renew air mass meter -G70- ⇒ Item 15 (page 84)
clear fault memory ⇒ page 8 , Reading and wclearing
gen AG fault
. Volkswagen AG
does
s a
memory. yV
olk not
gu b ara
ed
If display remains at approx. -40.0°C:
tho
ris nte
e or
au ac
– Press → button. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Continuation of check when display reads approx. 141.0°C:
es, in part or in w
t to the co
rrectness of i
If display jumps to approx. -40.0.0°C:
l purpos
nform
ercia

m
at
om
ion

c
in t
or
his
te

a
do
priv
cum
or

f
en
g

n
t.
yi Co
op
memory. C py
ht. rig
rig ht
by
If display remains at approx. -40.0°C: copy Vo
by lksw
cted agen
Prote
AG.

Checking lines:

Passat 1997 ➤
Motronic injection and ignition asystem
gen AG. V(5-cyl.
olkswag4-valve)
en AG
do - Edition 11.2009
w es n
olks ot g
yV ua
– Connect test box -V.A.G 1598/31- to control unitris
edwiring har‐
b ran
tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.
– Additionally check line for short-circuit to battery positive.
– Measure resistance at contacts 1 (signal) and 3 (earth) on in‐

take air temperature sender -G42- .

Passat 1997 ➤
Area A shows resistance values for

agen
AGtemperature
. Volkswagen AGrange 0…50°C
does
and area B the values forVotemperature
lksw range 50…100°C. not
g y ua
db ran
Examples: rise tee
tho or
au ac
♦ 30°C are inssrange A and correspond to a resistance of 1.5…
2.0 kΩ
ce
le
un
pt
an
d
itte
♦ 80°C are in range B and correspond to a resistance of 275…
y li
rm
ab
375 Ω
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
memory.
rrectness of i
l purpos
nform
2.7 Checking engine speed sender
mercia
a
The engine speed sender -G28- is a speed and reference mark
com
tion in
sender. The engine will not start if there is no speed signal. If the
r
te o
speed signal fails when the engine is running, it will cause the
thi
s
iva
engine to stall immediately. do

r
rp
cum
fo

en
ng
t.
yi Co
op
♦ Fault reader -V.A.G 1551- or vehicle system tester - C py
t. rig
gh ht
pyri by
Vo
co lksw
by
♦ Test box -V.A.G 1598/31- cted agen
Prote AG.

Test procedure
– Separate grey 3-pin connector -3- to engine speed sender.

Passat 1997 ➤
– Measure resistance of sender between contacts 2 + 3 at send‐

er connector.
• Specification: 480…1000 Ω
– Check the sender for short-circuit between contacts 1 + 2 as
well as 1 + 3.
– Renew engine speed sender -G28- ⇒ Item 17 (page 84) .
memory.
AG. Volkswagen AG d
If no sender fault is detected: agen oes
olksw not
y V gu
d b ara
ise nte
– Connect test box -V.A.G 1598/31- to control uunit
thor
wiring har‐ eo
ss a ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
– Additionally check wires for short to one another. cu

o
m
f
en
ng
t.
yi Co
If no fault in lines is detected: t. Cop py
rig
gh ht
– Remove sender and check sender wheel for secure seating, yri
p by
o Vo
damage and true running.
c by lksw
cted agen
Prote AG.
Note
There is a larger gap on the sender wheel. This gap is the refer‐
ence mark and does not mean that the sender wheel is damaged.
If no fault is detected on sender wheel:

2.8 Checking injectors

♦ Test box -V.A.G 1598/31-

Passat 1997 ➤

Test prerequisites
• Fuses No. 28 and 32 must be OK.
• The engine speed sender must be OK, checking
⇒ page 112 .
Test sequence:
WARNING agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b
Fuel system is under pressure!
rise
d Before opening the system arante
place a cloth around theut connection. Then release pressure by
ho eo
ra
carefully loosening sthe
s a connection. c
ce
e
nl
pt
du
an
itte
y li
Checking resistance of injectors
erm
ab
ility
ot p
– Disconnect 10-pin connector to injectors -2-.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Check resistance at connector to injectors between contacts:

1 + 6 for cylinder 1
• Specification: 13.0...19.0 Ω
Note
The resistance value is valid at approx. 20 °C. The resistance

value increases at higher temperatures.

– Remove intake manifold: ⇒ Rep. Gr. 15; Removing and in‐
stalling cylinder head; Removing and installing cylinder head
cover
– Check lines to relevant injector, or renew defective injector
⇒ Item 3 (page 87) .
Pay attention to the following when installing the injectors:
♦ Renew O-rings on all injectors and lightly moisten with clean
engine oil.
♦ Insert injectors vertically and in the correct position into the fuel
rail and secure with retaining clips.
AG. Volkswagen
♦ Fit fuel rail with secured injectorskswon cylinder head and press
agen AG do
es n
in evenly. y Vol ot g
ua
db e ran
ris tee
♦ The connectors mustuthaudibly
o engage when connected to the or
injectors. ss a ac
ce
e
nl
Checking activation and voltage supply

pt
du
an
itte
y li
10-pin connector to injectors remains disconnected.

erm
ab
ility
ot p
wit
– Additionally disconnect 8-pin connector -3- and therefore volt‐

, is n
h re
age supply to ignition coils.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤ agen
AG. Volkswagen AG d
oes
ksw not
Motronic injection
by Vand ignition system (5-cyl. 4-valve)
ol
gu - Edition 11.2009
a
ed ran
oris tee
– Connect diodeautest
th
lamp -V.A.G 1527- using auxiliary cables or a
from -V.A.G 1594-
ss to connector contacts 1 + 6 for cylinder 1 c
ce
of 10-pin connector to engine control unit. le
un
pt
an
d
itte
– Operate the starter and check the voltage supply for the in‐
y li
erm
ab
jector. The LED must light up.
ility
ot p
wit
– Repeat check on connector contacts:
is n
h re
ole,
spec
t to the co
rrectne
If the LED does not flicker:
ss o
cial p
f inform
mer
atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Check lines between test box and 10-pin connector for injec‐
tors for open circuit referring to current flow diagram.
Injector 1: Contact 2+ socket 96
– Additionally check wires for short to one another. Specifica‐
tion: ∞ Ω.
2.9 Checking injectors for leaks and quantity injected

Passat 1997 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne

♦ -V.A.G 1348/3- Remote control
ss o
cial p
♦ -V.A.G 1348/3-2- Adapter

inform
mer
♦ -V.A.G 1602- Injection rate tester

atio
om
Test prerequisite:
c
i
or
n thi
te
• The fuel pressure must be OK, checking ⇒ page 119 , check‐

sd
iva
ing fuel pressure regulator and holding pressure.

pr
cum
r
fo
en
ng
Test sequence:
t.
yi Co
Cop py
– Remove intake manifold: ⇒ Rep. Gr. 15; Removing and in‐ ht. rig
rig ht
by
stalling cylinder head; Removing and installing cylinder head copy Vo
by lksw
cover cted agen
Prote AG.
– Then remove fuel rail complete (fuel lines remains connected)

⇒ page 87 , dismantling and assembling fuel rail.
Checking for leaks:
– Introduce final control diagnosis ⇒ page 29 ; fuel pump must
run.

Passat 1997 ➤
Note
This step serves only to have the fuel pump running when the
engine is stopped.
– Check injectors for leaks (visual check). No more than 1 to 2

drops per minute must escape from each valve when fuel
pump is running.
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
Final control diagnosis and therefore the running sfuel pump are
au ra
c
switched off after one minute. s
ce
e
nl
pt
du
an
itte
If the fuel loss is greater:
y li
erm
ab
ility
ot p
wit
, is n
– Renew defective injector ⇒ Item 3 (page 87) .
h re
hole
spec
es, in part or in w
t to the co
engine oil.
rrectness of i
l purpos
♦ Fit fuel rail with injectors installed and secured onto lower part
of intake manifold and press in evenly.
nform
ercia
Checking quantity injected

m
at
om
io
n
c
in t
r

o
his
ate
do
riv
– Switch on ignition.
p
cum
for
en
g
– Bridge test box sockets 2 + 65 with auxiliary cables from -

n
t.
yi Co
V.A.G 1594- . The fuel pump must run. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
Note
cted agen
Prote AG.
This step serves only to have the fuel pump running when the
engine is stopped.
– Insert the injector to be checked into injection rate tester meas‐

uring glass -V.A.G 1602- .

Passat 1997 ➤
– Connect one contact of the injector to be tested to engine earth

using auxiliary cables from -V.A.G 1594- .
– Connect the second injector contact with auxiliary cable to re‐
mote control -V.A.G 1348/3- using adapter cable -
V.A.G 1348/3-2- .
– Connect crocodile clip to battery (+).
– Activate remote control -V.A.G 1348/3- for 30 seconds.
– Repeat check on other injectors. Use new measuring beakers.
– After all injectors have been activated, place measuring beak‐
ers on a level surface and compare the quantity injected.
Specification: 110...130 ml per injector
If the measured values of one or more injectors are above or be‐
low the prescribed specifications:
– Renew defective injector ⇒ Item 3 (page 87) .
engine oil.
♦ Fit fuel rail with injectors installed and secured onto lower part
of intake manifold and press in evenly.
memory.
2.10 Checking fuel pressure regulator and holding pressure
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
119
cted agen
Prote
2. Checking components
AG.
AG. Volkswagen AG d
agen oes
Passat 1997 ➤ olksw not
byV gu
ara
rised
- Edition 11.2009 nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
The fuel pressure regulator regulates the fuel pressure depending

on intake manifold pressure.
The specification for the check is dependent upon the working
pressure of the fuel pump. This is approx. 3.0 bar.
♦ -V.A.G 1318- K-Jetronic pressure tester
♦ -V.A.G 1318/1- Adapter
♦ -V.A.G 1318/10- Adapter
♦ -VAS 5024- Assembly tool for spring-type clips
Test sequence:
WARNING
Fuel system is under pressure! Before opening the system

place a cloth around the connection. Then release pressure by
carefully loosening the connection.

Passat 1997 ➤
– Use assembly tool for spring-type clips -VAS 5024- to remove

fuel supply pipe -2- (black or black marking) from fuel pressure
regulator.
– Connect K-Jetronic pressure tester -V.A.G 1318- to supply

pipe hose and fuel pressure regulator using adapters 1318/1
and 1318/10.
– Measure fuel pressure.
• Specification: approx. 2.5 bar
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Pull vacuum hose off fuel pressure regulator -arrow-. The fuel
pressure must increase to approx. 3.0 bar.
– Check vacuum system including vacuum reservoir (in left lkswage es n
hand wheel housing on A-pillar) for leaks. d byV
o ot g
ua
ran
ir se tee
– Check delivery rate of fuel pump. ⇒ Rep. Gr. 20; Removing utho
or
and installing parts of fuel supply system; Checking fuelsspump
a ac
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Now check for leaks and holding pressure. Do this by observ‐
ot
wit
, is n
ing pressure drop on gauge. After 10 minutes, there must be
h re
a residual pressure of at least 2.0 bar.
hole
spec
es, in part or in w
If the holding pressure drops below 2 bar:
t to the co
When the fuel pump has built-up the pressure again:
rrectness of i
– Switch ignition off after the pressure has built up. At the same
l purpos
time, close shut-off tap of K-Jetronic pressure tester -

V.A.G 1318- (handle transverse to direction of flow).
nform
ercia
– Again watch pressure drop on gauge.

m
a
com
t
If the pressure does not drop:
ion in
r
te o
– Check non-return valve for fuel pump: ⇒ Rep. Gr. 20; Re‐
thi
s
iva
moving and installing parts of fuel supply system; Checking
do
r
rp
c
fuel pump
um
fo
en
ng
t.
yi
If the pressure drops again:
Co
Cop py
t. rig
– Check pressure tester for leaks.
gh ht
pyri by
Vo
co lksw
by
– Check line connections, O-rings on fuel rail and injectors for cted agen
Prote AG.
leaks.
If no leaks can be found:
– Renew fuel pressure regulator.
When the K-Jetronic pressure tester is removed after the test has
been completed:
– Hold a cloth over the adapter to be loosened and remove K-
Jetronic pressure tester.
2.11 Checking intake manifold change-over

Perform check only if performance is poor.
The intake manifold changeover from long to short intake ports
occurs at approx. 4000 rpm.

Passat 1997 ➤
♦ Hand vacuum pump -V.A.G 1390-

Checking function
The change-over barrel in intake manifold is positioned at short
passageway.
– Have a second person press accelerator down to stop (throttle
burst). Observe vacuum unit for variable intake manifold.
n AG. Volkswagen AG age does
ksw
– The actuator must rotateby the change-over barrel in the intake
Vol
not
gu
ara
manifold -arrow-. rised
nte
tho eo
If the actuator does
ss
aunot perform the change-over movements: ra
c
ce
le

un
pt
an
d
itte
y li
– First check actuation of variable intake manifold changeover

rm
ab
valve -N156- via final control diagnosis ⇒ page 29 .

pe
ility
ot
wit
, is n
If valve actuation is OK:

h re
hole
spec
es, in part or in w
t to the co
– Pull vacuum hose -1- off at non-return valve -2-.

rrectness of i
– Connect hand vacuum pump -V.A.G 1390- to non-return valve

l purpos
-2-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤
– Perform final control diagnosis again. When the intake mani‐

fold changeover valve is actuated, operate hand pump evenly.
The actuator must switch back and forth between the two po‐
sitions.
If the changeover does not function as described:
– Check mechanical change-over components for ease of
movement. To do this, operate rods by hand.
– Check that vacuum lines are connected correctly.
– Check the vacuum system including the vacuum reservoir.
Note
Vacuum reservoir is secured in left hand wheel housing on A-

pillar.
2.12 Checking intake system for leaks (un‐

metered air)
Checking with engine leak detector spray G 001 800 A1
Note
♦ The vacuum in the intake system will cause the leak detector
spray to be drawn in with the outside air. The leak detector
spray reduces the ignitability of the mixture. This leads to a
drop in engine speed and to a change in Lambda probe value.
♦ The safety precautions listed on the container must be ad‐
hered to. agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
Special tools and workshop equipment required rise
d
nte
tho eo
♦ Fault reader -V.A.G 1551- or vehicle system tester - ss au ra
c
ce
e
nl
pt
du
an
♦ Engine leak detector spray G 001 800 A1
itte
y li
erm
ab
Test sequence:
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Select function XX
rrectness of i

l purpos

nform
ercia

m
at

om
ion

c
in t
or
his
ate

do
riv

p
1 2 3 4
um
for
en
ng
t.
yi
– Check whether the coolant temperature is above 85°C in dis‐
Co
op py
play zone 2. t. C rig
gh ht
pyri by
– Observe the engine speed in display zone 1 and Lambda con‐
co Vo
by lksw
cted
trol before catalytic converter in display zone 3.
agen
Prote AG.

Passat 1997 ➤
Display group 001 -Basic functions-


1
xxxx xx.x°C x.x% xxxxxxx
rpm x
Adjustment conditions for ba‐ 1x111111 ⇒ page 56
sic setting
Lambda control before catalytic convert‐ -10.0...10.0 % ⇒ page 67
er
Note
The display must hover around at least 0%. If 0 is constantly dis‐

played, Lambda control has switched from regulation to control
AG. Volkswagen AG d
because a fault has
olkswoccurred
agen in Lambda regulation
oes
not or probes are
not yet operational.
db
yV Read fault memory ⇒ page g8u .
ar
e an
ris tee
tho o
– Systematically
au spray parts of the intake system withr aengine
c
ss
leak detector spray.
ce
le
un
pt
If the engine speed drops or Lambda control changes:

an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n

h re

hole
spec
es, in part or in w

t to the co
– Check sprayed areas of intake system for leaks and rectify

fault if necessary.
rrectness of i
If the engine speed does not drop or Lambda control does not
l purpos
change:
nform
ercia

m

com
tion in
r

te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Passat 1997 ➤
3 Checking functions
3.1 Idling check
Note
♦ Idling speed, ignition timing and CO content not adjustable.

♦ Idling speed is regulated to specification by throttle valve po‐
sitioner in combination with DIS function.
♦ CO content is regulated to specification via Lambda control.
Lambda control malfunctions are ascertained by self-diagno‐
sis and stored in fault memory.

♦
Test prerequisites
• Exhaust system between catalytic converter and cylinder head
AG. Volkswagen AG d
must be free of leaks lkswagen oes
n
Vo ot g
by ua
• All electrical consumers, e.g.
ris
edlights and rear window heating, ran
tee
must be switched off. utho or
sa ac
• If the vehicle is equipped
s
with an air conditioner, it must be
ce
e
nl
switched off.
pt
du
an
itte
y li

erm
ab
04, display zone 3.

ility
ot p
wit
, is n
• Intake air temperature below 60°C ⇒ Display group 04, display

h re
zone 4
hole
spec
es, in part or in w
Test procedure
t to the co

rrectness of i

l purpos

memory.
nf
ercia
or
– Then:
m
m
atio
m
♦ Leave fault reader -V.A.G 1551- connected.

o
n in
or c
thi
e
♦ Continue to run engine at idling speed.

t
sd
iva
o
r
rp
cu
o

f
en
ng
yi Select function XX
t.
Co
op py
t. C rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote
AG.
Basic setting

1 2 3 4

Passat 1997 ➤
Note
In the “System in basic setting” function the activated charcoal

filter solenoid valve 1 -N80- is closed and the air conditioner com‐
pressor switched off.
AG. Volkswagen AG d
agen
– Check specifications for idlingVospeed
lksw in display zones 1...4.
oes
not
g y ua
db ran
rise Display zones tee
ho
ut or
1ss a 2 3 ac
4
ce
e
Display group 54: Idling speed check

nl
pt
du
an
itte
Readout xxxx rpm xxxxxxx xx.x% xx.x%
y li
erm
ab
Display Engine speed Operating status Accelerator position Throttle valve angle
ility
ot p
shows sender 1
wit
, is n
h re
Range 0...6800 rpm Idling speed, part throt‐ 0...97 % 0...100 %
hole
spec
tle , full throttle
es, in part or in w
overrun shut-off, en‐
t to the co
richment
Specifi‐ 650...750 rpm Idle 0...97 % 0...100 %
rrectness of i
cation
l purpos
3.2 Adapting idling speed
nform
mercia
In exceptional circumstances e.g. customer complaints concern‐
at
om
io
ing droning noises, vibrations at idling speed, adjusting idling
n
c
in t
r
speed slightly is permitted. In this case, however, ensure that the

o
his
e
idling speed is not outside the range printed in the exhaust emis‐
at
do
riv
sions test binder, (if the speed is outside the tolerance range, it is
p
cum
or
possible that the vehicle will fail the next exhaust emissions test).
f
en
ng
t.
yi Co
op
Special tools and workshop equipment required C py
t. rig
gh ht
yri
p by
co Vo
by lksw
V.A.G 1552- with cable -V.A.G 1551/3- Prote
cted AG.
agen
Test prerequisites
• No fault stored in fault memory
04, display zone 3.
Procedure
Select function XX
– Press buttons 1 and 0 for the function “Adaption” and confirm

input with Q button.
Indicated on display: Adaption
Feed in channel number XX
– Press buttons 0 and 1 for channel number 1 and confirm entry

with Q button.
Indicated on display: Channel 1 Adaptation xxx -
>
xxx rpm xxx rpm Text Text
3. Checking functions 127

Passat 1997 ➤ gen AG
. Volkswagen AG
does
swa
y Vsystem (5-cyl. 4-valve) - Edition
olk not 11.2009
gu
b ara
ed nte
ris
– Change the specified speed au
thin display zone 2
o
in jumps of 10 e or
ac
rpm with the following buttons:
ss -V.A.G 1551- : Buttons 1 and
ce
3 -V.A.G 1552- : Buttons ↑ and ↓
e
nl
pt
du
an
itte
y li
erm
Channel 1 Adaptation xxx -
ab
>
ility
ot p
xxx rpm xxx rpm Text Text
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The idling speed must not be adjusted to outside the permissible
idling speed range. The current idling speed value can be found
here ⇒ Data sheets for exhaust emission test.
rrectness of i
l purpos
– Confirm entry by pressing Q button.

nf
ercia
Channel 1 Adaptation xxx Q
o
Store amended figure?
rm
m
atio
m
– Store amended value by pressing Q button.

o
n in
or c
thi
te
sd
Channel 1 Adaptation xxx -
iva
>
o
r
rp
cu
Amended figure is stored
o
m
f
en
ng
t.
yi
– Finish adaption by pressing → key.
Co
Cop py
ht. rig
– Press keys 0 and 6 for function “End data transfer” and con‐ rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
3.3 Checking Lambda probe and Lambda

control before catalytic converter
Note
♦ Lambda probe (before catalytic converter) is subject to con‐

stant control and can be distinguished from Lambda probe
after catalytic converter via a 6-pin connector.
♦ Only gold-plated contacts may be used when repairing Lamb‐
da probe connector contacts.

♦ Test box -V.A.G 1598/31-

Passat 1997 ➤
Test prerequisites
must be free of leaks
04, display zone 3.
Functional check
Select function XX


1 2 3 4
– Check status of Lambda control before catalytic converter

(display zone 1). Specification: 1 1 1 AG. Volkswagen n AG do
wage es n
Significance of 3-digit number block in display zoney1:
Vol
ks ot g
ua
b
ed ran
oris tee
th
Significance
au if display = 1 or
ac
ss
1 2 3
ce
le
un
pt
an
d

itte
y li
rm
ab

pe
ility
ot

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– ⇒ page 65 , display group 30 and evaluation

If Lambda probe heating is not active, i.e. it constantly has the
specification 0:
rrectness of i
– Check Lambda probe heating before catalytic converter

l purpos
⇒ page 91 .
If Lambda probe or Lambda control are not active:
nform
ercia
– Change to display group 32 as follows:

m
a
com
tion in

r
te o
thi
s
iva

do
r
rp

um
fo
en
ng
t.
yi
Co
Cop Read measured value block 32 py ->
t. 1 2 3 rig 4
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
– Check Lambda learnt values at idling speed (additive) in dis‐

play zone 1. Specification: -5.4...5.4%
– Check Lambda learnt values at part throttle (multiplicative) in
display zone 2. Specification: -10.0...10.0%
If one or more specifications are not attained:
– Change to display group 33 as follows: -V.A.G 1551- : Press
key 3 -V.A.G 1552- : Press key ↑
1 2 3 4

– Observe Lambda control in display zone 1. Display must fluc‐
tuate by at least 2% in range from -10.0...10.0%.
– Check Lambda probe voltage in display zone 2. Voltage must
be at least 1.35 V.
If one or both displays in zones 1 and 2 do not indicate the spec‐
ification:
– Check Lambda probe lines ⇒ page 131 .
Continuation
If Lambda control in display zone 1 does not fluctuate in specified
range:
– Take car for a road test to free Lambda probe of any deposits,
then repeat the test. AG. Volkswagen AG d
agen oes
ksw
Observe applicable safety precautions during road test byV
ol not
gu
⇒ page 89 . rised ara
nte
ho eo
ut
If the the specifications in display zone 1 are not obtained
ss a even ra
c
after a road test, or the value does not fluctuate by at least 2 %:
ce
le
un
pt
an
– Check Lambda probe before catalytic converter for ageing

d
itte
y li
⇒ page 134 .
erm
ab
ility
ot p
Possible causes of faults if probe control frequency is too slow:

wit
is n
h re
♦ The slots or holes in probe body are blocked

ole,
spec
♦ The probe vent hole in area of connection cable is sealed

t to the co
♦ The probe has been overheated (glazed)

♦ The probe has been damaged by leaded fuel
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
130
Prote AG.
Rep. Gr.24 - Mixture preparation - injection
Passat 1997 ➤
Check Lambda probe lines:

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Disconnect 6-pin connector -1- (black) to Lambda probe 1 -
es, in part or in w
G39- before catalytic converter.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
– Check lines between test box and 6-pin connector (to control
p
cum
for
unit) for open circuit referring to current flow diagram.
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
Contact 2+ socket 71 cop Vo
by lksw
cted agen
Prote AG.
– Additionally check all lines for short-circuit to one another.
– Renew Lambda probe bank 1 -G39- .
3.4 Checking Lambda probe and Lambda

control after catalytic converter
Note
Only gold-plated contacts may be used when repairing Lambda

probe connector contacts 3 and 4.

♦ Test box -V.A.G 1598/31-

Passat 1997 ➤ AG. Volkswagen AG d
agen
V olks-w Edition 11.2009
oes
not
y gu
db ara
ise nte
♦ Auxiliary measuring set -V.A.G 1594- tho
r eo
au ra
c
♦ Current flow diagram ss
ce
le
un
pt
Test prerequisites
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
must be free of leaks
hole
spec
es, in part or in w
t to the co
04, display zone 3.
Functional check
rrectness of i
l purpos

nform
mercia
a
com
tio
Select function XX
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Input display group number XXX by c lksw
cted agen
Prote AG.
1 2 3 4
– Check status of Lambda control after catalytic converter (dis‐

play zone 2): Specification: 1 1 0
Note
Bits in display zone 2 are only set to 1 when catalytic converter

temperature has exceeded 350°C and a part throttle signal has
been detected by engine control unit.
Significance of 3-digit number block in display zone 2:
1 2 3

If Lambda probe heating is not active, i.e. it constantly has the
specification 0:
– Check Lambda probe heating after catalytic converter
⇒ page 93 .

Passat 1997 ➤
If Lambda probe or Lambda control after catalytic converter are

not active:
Checking basic voltage
– Disconnect 4-pin connector (brown) -2- to Lambda probe 2
bank 1 -G130- after catalytic converter.
– Connect multimeter with auxiliary cables from -V.A.G 1594- to

measure voltage at contacts 3 + 4 (connector to Motronic con‐
trol unit).
– Start engine and measure basic voltage. Specification:
0.40...0.50 V . Volkswage n AG n AG d
wage oes
– Switch off ignition. Volks not
gu
by ara
ed
oris nte
eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
– Connect test box -V.A.G 1598/31- to control unit wiring har‐ wit
, is n

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
– Check lines between test box and 4-pin connector to Motronic

r
te o
thi
control unit for open circuit referring to current flow diagram.

s
iva
do
r
rp
um
fo
en
ng
t.
yi Co
Cop py
ht. rig
• Cable resistance: max. 1.5 Ω. rig ht
py by
co Vo
by lksw
If specification is attained: cted agen
Prote AG.
– Renew Lambda probe after catalytic converter.

memory.

Passat 1997 ➤
3.5 Checking Lambda probe ageing of

Lambda probe 1 before catalytic con‐
verter G. Volkswage A n AG d
agen oes
Special tools and workshop equipment required ksw not
y Vol gu
b ara
ed
♦ Fault reader -V.A.G 1551- or vehicle system
horis tester - nte
eo
V.A.G 1552- with cable -V.A.G 1551/3-s aut ra
c
s
Test prerequisite
ce
e
nl
pt
du
an
• Coolant temperature must be at least 85 °C, ⇒ display group itte
y li
erm
ab
04, display zone 3.
ility
ot p
wit
Functional check
, is n
h re
hole
spec
es, in part or in w
t to the co
Select function XX
rrectness of i
l purpos
nf
ercia
o
Basic setting
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
System in basic setting 34 ->
o
m
f
1 2 3 4
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote
AG.
1800 rpm.
– Allow engine to run at increased speed until the display in dis‐
play zone 4 jumps from “Test OFF” to “Test ON”. The catalytic
converter temperature in display zone 2 should be at least 350
°C.
Note
This procedure can take several minutes.
– Leave engine running at increased speed until the specifica‐

tion "B1 -S1- OK" is displayed in display zone 4.
then repeat the test.
⇒ page 89 .
If the specifications are again not attained:
– Renew Lambda probe 1 bank 1 before catalytic converter -
G39- ⇒ Item 19 (page 84) .

Passat 1997 ➤
Note

must be erased ⇒ page 142 .

memory.
3.6 Checking Lambda probe ageing of

Lambda probe after catalytic converter
(adaptation)
♦ Fault reader -V.A.G 1551- or vehicle system tester - swage
es n
V.A.G 1552- with cable -V.A.G 1551/3- byV
olk ot g
ua
d ran
ir se
Test prerequisite tho tee
or
au ac
ss
ce
le
04, display zone 3.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Select function XX
es, in part or in w
t to the co
rrectness of i
Function test for Lambda probe 2 bank 1
l purpos

nform
ercia

m
a
com
tion in
r
System in basic setting 43 ->

te o
thi
1 2 3 4
s
iva
do
r
rp
c
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
1800 rpm. cop Vo
by lksw
cted agen
Prote AG.
– Allow engine to run at increased speed until the display in dis‐
play zone 4 jumps from “Test OFF” to “Test ON”. The catalytic
converter temperature in display zone 2 should be at least 350
°C.
Note
This procedure can take several minutes.
– Leave engine running at increased speed until the specifica‐

tion “B1 S2 OK” is displayed in display zone 4.
then repeat the test.

Passat 1997 ➤
Motronic injection and ignition system (5-cyl. 4-valve) - Edition
wa11.2009
gen AG
. Volkswagen AG
doe
ks s no
Vol t gu
by ara
Observe applicable safety precautions during road test ris
ed
nte
⇒ page 89 . autho eo
ra
ss c
– Check Lambda probe and Lambda control after catalytic con‐
ce
e
nl
verter ⇒ page 131 .
pt
du
an
itte
y li
If the specifications are again not attained:
erm
ab
ility
ot p
– Renew Lambda probe after catalytic converter -G130- .
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
must be erased ⇒ page 142 .
rrectness of i
3.7 Checking engine operating statuses
l purpos
nf
ercia
o
Note
rm
m
atio
om
n in
The check determines whether engine control unit recognises the
or c
engine operating statuses idling speed, overrun, part throttle, full
thi
te
sd
a
throttle and enrichment.

iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t.
rig
gh ht
yri by
V.A.G 1552- with cable -V.A.G 1551/3- cop Vo
by lksw
cted agen
Prote
Test prerequisite
AG.

04, display zone 3.
Test procedure
Select function XX
– Press buttons 0 and 8 for function “Read measured value

block” and confirm entry with Q button.

1 2 3 4
– Check whether the control unit recognises the operating sta‐

tuses (display zone 4):
♦ Idling speed:
As long as the engine is running at idling speed, idling speed must
be displayed.
Display: Idling speed
♦ Part throttle:
– Rev up evenly.
As long as the engine is being revved up evenly, part throttle must
be displayed.

Passat 1997 ➤
Display: Part throttle

♦ Enrichment:
– Floor accelerator (onto throttle valve stop).
Acceleration enrichment must be displayed briefly.
AG. Volkswagen AG d
Display: Enrich. agen oes
o lksw not
y V gu
d b ara
♦ Overrun mode: orise nte
th eo
u ra
– Increase engine
ss a speed to above 3000 rpm. c
ce
e
nl
– Then close throttle abruptly.
pt
du
an
itte
y li
Display: Overrun
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w
♦ A road test may have to be performed to show achieve overrun
t to the co
in display.
♦ A 2nd person is required when performing a road test.
rrectness of i
♦ Full throttle:
l purpos
– Floor accelerator (onto throttle valve stop).
nform
ercia
Full throttle must be displayed briefly.

m
at
Display: Full throttle
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
g
♦ A road test may have to be performed to achieve full throttle

n
t.
yi Co
op
in display. C py
t. rig
gh ht
yri by
♦ A 2nd person is required when performing a road test. cop Vo
by lksw
cted agen
Prote AG.
WARNING
Secure fault reader to rear seat and operate from this position.

⇒ page 89 .
If the specifications are not attained:
– Check throttle valve module ⇒ page 99 .
memory.

Passat 1997 ➤
4 Engine control unit
4.1 Checking control unit voltage supply

♦ Test box -V.A.G 1598/31- AG. Volkswagen AG d
agen oes
olksw not
♦ Hand multimeter -V.A.G 1526- d by or multimeter -V.A.G 1715-
V gu
ara
ise nte
r
♦ Auxiliary measuring setut-V.A.G 1594-
ho eo
ra
s a c
s
ce
le
un
pt
an
Test prerequisites
d
itte
y li
rm
ab
• All fuses must be OK.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
switched off.
rrectness of i
• Alternator OK, check: ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
l purpos
Test procedure
nform
ercia

m
a
com
ti

on in
r
te o
thi
s
iva
do
r
rp
cum

fo
en
g
Select function XX
n
t.
yi Co
op py
– Press keys 0 and 8 for function “Read measured value block” t. C rig
gh ht
and confirm entry with Q key. pyri by
Vo
o
by c lksw
cted agen
Read measured value block HELP


1 2 3 4
– Read off figure displayed in display zone 2. Specification: At

least 11.5 V
– Press keys 0 and 6 for function “End data transfer” and con‐

Passat 1997 ➤

Checking voltage supply terminal 30
– Measure supply voltage between test box sockets 1+62 using
multimeter and test leads from -V.A.G 1594- : Specification:
At least 11.5 V
– Check wiring connections to relay plate referring to current
flow diagram: ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
Checking voltage supply terminal 15
– Measure supply voltage between test box sockets 2+3 using
multimeter and test leads from -V.A.G 1594- : Specification:
At least 11.5 V
– Check wiring connections to relay plate referring to current
flow diagram: ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
memory.
AG. Volkswagen AG d
agen oes
ksw
4.2 Procedure after voltage supply open cir‐ ol not
y V gu
d b ara
ise
cuit r nte
tho eo
au ra
s c
All values learnt by the engine control unit and the basic setting s
ce
le
values as well as the readiness code will be cleared if the voltage

un
pt
an
d
supply is interrupted. Therefore, depending upon the vehicle mile‐

itte
y li
age it can lead to serious engine running problems.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Procedure
Perform the following operations after voltage supply open circuit:
– Switch ignition on for at least 10 seconds. rrectnes
s o
cial p
– Adapting engine control unit to throttle valve module

inform
⇒ page 143 .
mer
atio
m
– Carry out idling speed test ⇒ page 126 .

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
r
fo
en
ng
t.
During idling check the activated charcoal filter solenoid valve and
yi Co
op py
the air conditioner are switched off and the Lambda regulation t. C rig
gh ht
learning procedure is initiated. yri
p by
co Vo
by lksw
cted agen
Prote AG.
– Perform a longer road test until the engine running problems
are eliminated.
⇒ page 89 .
4. Engine control unit 139

Passat 1997 ➤

AG. Volkswagen AG d
met: ksw
agen oes
not
ol
yV gu
♦ The coolant temperature must exceed 80°C. ised b ara
n r tee
ho
♦ When the temperature is reached, the operating statuses
sa
ut or
ac
idling speed, part throttle, full throttle and overrun must be at‐
s
ce
le
tained several times.
un
pt
an
d
itte
y li
♦ At full throttle, the speed must exceed 3500 rpm.
erm
ab
ility
ot p
4.3 Renewing engine control unit
wit
is n
h re
ole,
The engine control unit regulates the injection, throttle valve con‐
spec
trol module, Lambda regulation, ignition, knock control, activated urposes, in part or in wh
charcoal filter solenoid valve 1, speed limitation via injectors or
t to the co
fuel pump relay, camshaft adjustment as well as self-diagnosis
If the engine control unit has been renewed in vehicles with au‐
rrectne
tomatic transmission, the kick-down point must be learnt again.
Checking kick-down point ⇒ page 151
ss
o
cial p
f inform
♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3-
mer
atio
Procedure
om
n
c
i
or
n
– First print out the control unit identification and thereby the
thi
te
previous control unit coding as follows:
sd
iva
o
pr
cum
r

fo
en
ng

t.
yi Co
op
01. (Connect fault reader and select engine control unit C py
ht. rig
⇒ page 4 ) rig ht
py by
co Vo
by lksw
The control unit identification and coding are indicated on display, cted agen
Prote 066906032J MOTRONIC ME7.1
AG. G 001 ->
e.g.: Coding 00131 WSC 00000
In vehicles as of model year 2001, the 17-digit chassis number WVWZZZ3BZ1E035486 VWZ7Z0Y2574101
and the 14-digit immobiliser ID number are additionally displayed,
e.g.:
– Print out the control unit identification by pressing the fault
reader Print button.
Select function XX

– Remove cover from protective housing for control units.
– To do this, turn cover with its raised side approx. 180° (1/2
turn) to left and remove.

Passat 1997 ➤
– Carefully lever off the retaining bar with a screwdriver

-arrow-.
– Then release connectors on control unit and pull off.
– Remove old control unit and insert new
wage one.
es ks not
Vol gu
– Check previous coding and ecode
db
y new control unit ara
nte
⇒ page 141 . thoris eo
au ra
– Adapting new enginesscontrol unit to throttle valve module c
ce
le
⇒ page 143 .
un
pt
an
d
itte
– Vehicles with cruise control system: Check whether this func‐
y li
erm
ab
tion is activated ⇒ page 4 . If “G” does not appear in control
ility
ot p
unit identification, activate cruise control system. ⇒ Current
wit
is n
flow diagrams, Electrical fault finding and Fitting locations
h re
ole,
spec
– Then subsequently read fault memory of the new engine con‐
trol unit and clear fault memory if necessary.
t to the co
– Carry out idling speed test ⇒ page 126
rrectne
4.4 Coding engine control unit
ss o
cial p
f
Note
inform
mer
atio
♦ A 5-digit code must always be displayed during control unit
om
identification.
n
c
i
or
n thi
e
♦ If the appropriate code for the vehicle is not displayed or if the

t
sd
va
control unit has been renewed, the control unit must be coded
i
o
pr
cum
r
as follows.
fo
en
ng
t.
yi Co
Cop py
Special tools and workshop equipment required ht. rig
rig ht
py by
o Vo
♦ Fault reader -V.A.G 1551- with cable -V.A.G 1551/3- by c lksw
cted agen
Prote AG.
Procedure
⇒ page 4 )
Select function XX
– Press keys 0 and 7 for function “Code control unit” and con‐
Indicated on display: Code control unit
Enter code number XXXXX (0-32000)
– Enter appropriate code number for vehicle and confirm with

Q key.
Coding variants:
The code number is compiled as shown in the following example:
1st digit 2nd digit 3rd digit 4th digit 5th digit
vehicle exhaust emissions special coding CAN bus gearbox
0 0 0 = front-wheel drive 1 = ABS 1 = 5-speed
1 = four-wheel drive 2 = airbag 2 = 6-speed
3 = ABS+airbag 3 = autom. gearb.
0 0 1 3 1

Passat 1997 ➤
The control unit identification and coding are indicated on display, 066906032J MOTRONIC ME7.1 G 001 ->
e.g.: Coding 00131 WSC 00000
Indicated on display when a non-authorised code number has Function is not recognised or cannot ->
been entered. be performed at the moment.
memory.
Note
♦ The code unit entered and shown on the display will not be
used by the Motronic control unit until the ignition has been
switched off once. Incorrect coding leads
agen to:
AG. Volkswagen AG d
oe w s no
olks
♦ Engine running faults (gear change jerks, load change jerks,
V t gu
by ara
ed
etc.) ris nte
utho eo
ra
a
♦ Increased fuel consumption
ss c
ce
e
nl
♦ Increased exhaust emissions

pt
du
an
itte
y li
♦ Storage of non-existent faults in fault memory
erm
ab
ility
ot p
♦ Functions will not be performed (Lambda regulation, activation

wit
, is n
of the activated charcoal filter system, etc.). h re

hole
spec
♦ Reduced gearbox life
es, in part or in w
t to the co
4.5 Erasing learnt values of control unit for

engine electronics
rrectness of i
If injectors or one of the Lambda probes are renewed, learnt val‐

l purpos
ues in engine control unit must be erased, as engine running

problems may otherwise occur.
nf
ercia

rm
m
atio
m

o
n in
c

or
thi
te
sd
iva
Procedure
o
r
rp
cu
o
m
f

en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri
⇒ page 4 )
p by
co Vo
by lksw
cted agen
Prote AG.
Select function XX

display:
– Enter 10 for “Adaptation” function and confirm with Q.
Indicated on display: Adaption
Feed in channel number XX
– Enter 00 for channel number 0 and confirm with Q.

Indicated on display: Adaption Q
Erase learnt values?

Passat 1997 ➤
– Confirm entry by pressing Q button.

Indicated on display: Adaption ->
Learnt values have been cleared
– Finish adaptation by pressing → button.

– Adapting engine control unit to throttle valve control module
⇒ page 143 .
4.6 Adapting engine control unit to throttle

valve control module
The adaption process enables the engine control unit to learn the
different positions of the throttle valve with the ignition switched
on and the engine not running. These positions are stored in the
control unit. The feedback of the throttle valve position is via both
throttle valve drive angle senders.
Adaptation must be performed if:
♦ The supply voltage has been interrupted
♦ The throttle valve module has been removed and installed
♦ The throttle valve module has been renewed
♦ Another throttle valve module has been installed due to instal‐
lation of another engine
Test prerequisite lkswage es n
o ot g
byV ua
d ran
• No faults must be stored in fault memory
o
ir se ⇒ page 8 , Reading tee
and erasing fault memory. auth or
ac
ss
ce
le
un
pt
an
d

itte
y li
erm

ab
ility
ot p
• The throttle valve must be at idling speed position.

wit
is n
h re
ole,
Procedure
spec

t to the co

⇒ page 4 )
rrectne

s
Select function XX
s o
cial p

inform

mer
atio
m
o
Basic setting
c
i
or

thi
te
sd
a

iv
o
pr
cum

r
fo
en
ng
t.
yi Co
Indicated on display: (1…4 = display zones) t. Cop py
System in basic setting 60
rig ->
gh 1 2 3
ht 4
pyri by
Vo
co lksw
by
After pressing the Q button, the throttle valve positioner is switch‐ Prote
cted AG.
agen
ed so that it is not supplied with voltage.
In this condition the throttle valve is pulled into an emergency
running or default position by a spring in the throttle valve control

Passat 1997 ➤
module. The values that both angle senders provide in this emer‐
gency running position are stored by the engine control unit.
The throttle valve is then opened by a predetermined amount. If
this value is achieved, the throttle valve positioner is again switch‐
ed so that it is not supplied with voltage. Now the mechanical
spring must close the throttle valve to the previously learnt emer‐
gency running position within a predetermined period (spring
test).
Then the throttle valve is closed by the throttle valve positioner
and the values, which are supplied by the angle senders in the
throttle valve control module are stored by the engine control unit.
If the engine control unit switches the throttle valve positioner so
that it is without voltage during normal operation, this is indicated
by the increased and hunting idling speed. The engine only reacts
slowly to accelerator changes.
– Check specifications (display zones 1...4):
1 2 3 4
– End adaptation after 30 seconds at the earliest by pressing →

button.
Adaptation has been performed successfully.
To store the values:
Note
♦ If basic setting of the control unit is aborted, the cause could

be one of the following: AG. Volkswagen AG d
agen oes
ksw
♦ Throttle valve cannot reach the mechanical idling speed stop by V ol not
gu
because of contamination e.g. carbon deposits. rised ara
nte
ho eo
♦ Battery voltage too low. aut ra
ss c
ce
le
♦ Throttle valve module or connecting line is defective, checking

un
pt
⇒ page 99 .
an
d
itte
y li
erm
ab
♦ After an abortion, a fault is stored in fault memory. When next
ility
ot p
switching on ignition, basic setting is automatically performed

wit
is n
again.
h re
ole,
spec
– End engine basic setting by pressing the → button. t to the co

rrectne

s
4.7 Teaching-in kick-down point

s o
cial p
f in
If the engine control unit or accelerator has been renewed in ve‐

form
mer
hicles with automatic transmission, the kick-down point must be

atio
learnt again.
om
n
c
i
or
Test prerequisite
thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
Test procedure
t.
yi Co
op py
t. C rig
gh ht
yri
ignition on and select engine control unit with “Address word” p by
o Vo
by c
lksw
cted agen
Prote
⇒ page 4 )
AG.

Passat 1997 ➤

Select function XX

Indicated on display: Basic setting HELP

Indicated on display: System in basic setting 63 ->
1 2 3 4
– Observe the display in display zones 3 and 4: Display: Actuate

kick-down
– Press accelerator past kick-down point to stop.
. Volkswagen AG
gen AG
– Hold accelerator at stopVfor
olks at least 2 seconds.
wa does
not
by gu
d ara
– Observe the display orisein display zones 3 and 4: Specification: nte
Kick-down ADP. aut running, then specification: Kick-down ADP e or
h
ac
O.K ss
ce
le
un
pt
– If following display appears in display zones 3 and 4: Kick-
an
d
itte
down ERROR
y li
rm
ab
pe
ility
– End engine basic setting by pressing the → button.
ot
wit
, is n
h re
hole
spec
es, in part or in w
– Checking accelerator position sender: ⇒ Rep. Gr. 20; Check‐

ing electronic engine output control (electronic throttle control); t to the co
Checking accelerator position sender rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
5 Checking additional signals
5.1 Checking speed signal

♦ Test box -V.A.G 1598/31-
Test prerequisites
• The speedometer must be OK. Checking speedometer: ⇒
Electrical system; Rep. Gr. 90
Test procedure
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
by ara
d
To check the speed signal the vehicle
orismust
e
be driven. To do this nte
eo
a second person is necessary. s a th
u ra
s c
ce
e
nl
pt
du
an
itte
WARNING y li
erm
ab
ility
ot p
Secure fault reader to rear seat and operate from this position.
wit
, is n
h re
hole
spec

es, in part or in w
t to the co

rrectness of i

Select function XX
l purpos

nf
ercia
rm
m

atio
m

o
n in
or c

thi
te
sd

iva
o
r
rp
cu
o

f
en
ng
Read measured value block 5

t. ->
yi 1 Co
2 3 4
Cop py
t. rig
gh
– Carry out road test with a 2nd person to observe display.
ht
pyri by
Vo
co lksw
by
– Observe figure displayed in display zone 3: Specification: Ap‐ cted agen
Prote AG.
prox. road speed
If no speed is displayed:

Passat 1997 ➤
olkswagen AG
en AG. V
– Connect test box -V.A.G 1598/31- to control unit wiring kshar‐
wag does
not
Vol
ed
by gu
ara
ris nte
– Connect multimeter to measure voltage between
au
tho test box eo
ra
sockets 3 (terminal 15) + 54 (speed signal).
ss c
ce
e
nl
pt
du
an
itte
y li
– Lift vehicle at front left.
erm
ab
ility
ot p
– Rotate front wheel and observe voltage display. Specification:
wit
, is n
between 0 and at least 4 volt fluctuating
h re
hole
spec
If the display does not fluctuate:
es, in part or in w
t to the co
– Check lines to speedometer or speedometer sender: ⇒ Cur‐
rrectness of i
5.2 Checking signals from and to air condi‐
l purpos
tioning system
nf
ercia
orm
m
atio
m

o
n in
or c
thi
♦ Test box -V.A.G 1598/31-
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Checking additional signals 147

Passat 1997 ➤
Test prerequisites
• The function of the air conditioning system must be OK.
• Fuse 31, in vehicles with front-wheel drive, must be OK.
• Air conditioner must be switched off
ating fault memory.
• Vehicle at room temperature (warmer than + 15 °C).
Test procedure
Select function XX
lkswage es n
o ot g
– Press keys 0 and 8 for function “Read measured value block” d by V ua
ran
e
and confirm entry with Q key. horis tee
ut or
a ac
Indicated on display: ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 2 3 4
– Observe display in display zone 4. It must show Compr. OFF.
rrectness of i
– Switch on air conditioning system.
l purpos
– Set lowest temperature and highest blower speed.
nform
ercia
The display in display zone 4 must change to Compr. ON.

m
at
om
ion
c
in t
or

his
ate
entry with Q button. do

priv
cum
for

en
ng
t.
yi Co
op py
If the display does not change: t. C rig
gh ht
pyri by
Vo
co lksw
by
– Connect test box -V.A.G 1598/31- to control unit wiring har‐ Prote
cted AG.
agen
– Check lines for open circuit between sockets 40 + 41 and air
conditioner using current flow diagram. Cable resistance: max.
1.5 Ω.

Passat 1997 ➤
5.3 Checking signal from clutch pedal

switch
♦ Test box -V.A.G 1598/31-
Note
This signal is necessary to avoid load change jolts in the cruise

control system.
Test procedure
⇒ page 4 )
Select function XX

– Press keys 0 , 6 and ge6n Afor

G. V“Display
olkswagengroup
AG do number 66” and
swa es n
confirm entry ywith
Vo lk Q key. ot g
u
db ara
se nte
Indicated on
tho display:
ri e or Read measured value block 66 ->
au ac 1 2 3 4
ss
ce
e
– Observe display in display zone 2. (6th position from left)

nl
pt
du
an
Specification: x x x x x 0 x x
itte
y li
erm
ab
– Fully depress clutch pedal and observe the display in display

ility
ot p
zone 2. Specification: x x x x x 1 x x
wit
, is n
h re
hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos
– Remove driver's storage compartment: ⇒ General body re‐

pairs, interior; Rep. Gr. 68 ; Dash panel; Removing driver's
nf
ercia
storage compartment .
orm
m
atio
– Checking clutch pedal switch -F36- and line connections ac‐

om
cording to current flow diagram: ⇒ Current flow diagrams,

n in
or c
Electrical fault finding and Fitting locations

thi
te
sd
iva
5.4 Checking signal from brake light switch

r
rp
cu
o
m
f
en
and brake pedal switch

ng
t.
yi Co
Cop py
ht. rig
Special tools and workshop equipment required rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Passat 1997 ➤

♦ Test box -V.A.G 1598/31-
Test procedure
⇒ page 4 )
Select function XX

lkswage es n
– Press keys 0 , 6 and 6 for “Display
by V group number 66” and
o ot g
ua
d ran
confirm entry with Q key. orise tee
th or
u
Indicated on display: ss
a ac
ce
le
1 2 3 4
un
pt
an
d
itte
– Observe displays in display zone 2: (1st and 2nd positions

y li
erm
ab
from right) Specification: x x x x x x 0 0
ility
ot p
– Depress brake pedal and observe display in display zone 2. wit

is n
h re
Specification: x x x x x x 1 1
ole,
spec
t to the co

rrectne

ss o
cial p
– Remove driver's storage compartment: ⇒ General body re‐

inform
pairs, interior; Rep. Gr. 68 ; Dash panel; Removing driver's

mer
storage compartment .
atio
om
n
c
– Checking brake light switch -F- , brake pedal switch -F47- and
i
or
n thi
line connections according to current flow diagram: ⇒ Current

te
sd
va
flow diagrams, Electrical fault finding and Fitting locations.

i
o
pr
cum
r
fo
5.5 Checking driving range signal

en
ng
t.
yi Co
Cop py
.
Vehicles with automatic gearbox only
t rig
gh ht
pyri by
Vo
co
Engine control unit receives following information from gearbox
by lksw
cted agen
Prote
control unit: Driving range selected (selector lever in 2/3/4/R/D)
AG.
or No driving range selected (selector lever in P or N)

♦ Test box -V.A.G 1598/31-

Passat 1997 ➤
Test prerequisite
• The selector lever of the automatic gearbox must be in “P” or
“N” position.
Test procedure
⇒ page 4 )
Select function XX


1 2 3 4
– Observe display zone 4. The display must be set to specifica‐

tion: x x x 0 x “Neutral”.
– Depress foot brake and select driving range. The display must
jump to Specification: x x x 1 x “Driving range engaged”.
entry with Q button. Volkswa . gen AG
gen AG does
swa
– Switch off ignition. yV
olk not
gu
db ara
se
If the display does not change: tho
ri nte
eo
au ra
– Check matching resistor
s for data bus ⇒ page 152
s c
ce
e
nl
pt
5.6 Checking kick-down point

du
an
itte
y li
erm
ab
Vehicles with automatic gearbox only

ility
ot p
wit
If the engine control unit, the throttle valve module or the elec‐
, is n
h re
tronic throttle have been renewed, the kick-down point must be

hole
spec
learnt again.
es, in part or in w
t to the co
Test prerequisite
rrectness of i

ating fault memory.
l purpos
• The selector lever of the automatic gearbox must be in “P” or

“N” position.
nf
ercia
orm
Test procedure
m
atio
om
n in
c

or
thi

te
sd
a

iv
o
r
rp
cu
⇒ page 4 )
o
m
f
en
ng
t.
yi
Co
Cop Rapid data transfer
py HELP
ht. rig
Select function XX
rig ht
py by
o Vo
– Press keys 0 and 4 for function “Initiate basic settings” and by c lksw
cted agen
Prote
AG.

Passat 1997 ➤
Indicated on display: Basic setting HELP


1 2 3 4
– Observe the display in display zones 3 and 4: Display: Actuate

kick-down
– Press accelerator past kick-down point to stop.
– Hold accelerator for at least 2 seconds against stop.
– Observe the display in display zones 3 and 4: Specification:
Kick-down ADP. running, then specification: Kick-down ADP
O.K
– If following display appears in display zones 3 and 4: Display:
Kick-down ERROR
– Check accelerator position senders G79 and G185. ⇒ Rep.
Gr. 20; Electronic engine output control (electronic throttle
control); Checking accelerator position sender ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
5.7 Checking matching resistor for data bus

Function
The engine control unit communicates with other data bus com‐
patible control units.
The control units are connected together via two data bus lines
twisted together (High and Low), and exchange information (mes‐
sages). Information not available on the data bus is recognised
as a fault by both the engine control and other data bus control
units.
AG. Volkswagen
The data bus requires a matching resistor lkswto function fault-free. es not
agen AG do
This central matching resistor is located
db
y V in the engine control unit.
o gu
ar
e an
ris tee
Test prerequisite utho or
a ac
ss
• A data bus fault has been detected by self-diagnosis
ce
e
nl
pt
du

an
itte
y li
erm
ab
♦ Test box -V.A.G 1598/31-

ility
ot p
wit

, is n
h re
hole

spec
es, in part or in w

t to the co
Test procedure
rrectness of i

l purpos
– Release connector from engine control unit and pull off.

– Connect test box -V.A.G 1598/31- to engine control unit. The
nform
ercia
control unit wiring harness is not connected by this action.

m
– Check central matching resistor in engine control unit.

at
om
ion
c
in t
– To do this perform resistance measurement between test box

or
his
e
sockets 58 + 60: Specification: 60…72 Ω

at
do
priv
If resistance measurement is outside specified range:

um
for
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
AG. Volkswagen AG d
If the resistance value is within the specifiedlkrange:
swa
gen oes
not
o
yV gu
– Eliminate the fault: ⇒ Current flowrisdiagrams,
ed
b
Electrical fault ara
nte
finding and Fitting locations uth o eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Passat 1997 ➤
28 – Ignition system
1 Repairing ignition
1.1 General notes on ignition system

swa
gen AG
. Volkswagen AG
does
k not
Vol gu
♦ Only the components which specifically by
ed relate to the ignition
ara
ris components of the in‐ nte
system are dealt with here. For other
tho eo
jection and ignition system, ⇒ ssRep.
au Gr. 24 . ra
c
ce
e
♦ The engine control unit has a self-diagnosis capability.

nl
pt
du
an
itte
y li
♦ Components marked with * are checked via self-diagnosis
erm
ab
⇒ page 8 , Reading and erasing fault memory.
ility
ot p
wit
♦ For trouble-free operation of electrical components, a voltage
, is n
h re
of at least 11.5 V is necessary.
hole
spec
♦ Certain tests may lead to a fault being detected by the control
es, in part or in w
t to the co
unit and stored. Therefore, after completing all checks and re‐
pairs the fault memory must be read and if necessary erased
⇒ page 8 , reading and erasing fault memory
rrectness of i
Safety precautions ⇒ page 157 .
l purpos
Spark plug test data ⇒ page 157 .
1.2 Removing and installing parts of ignition
nform
ercia
system
m
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
en
Engine control unit with connectors ⇒ Item 5 (page 83) .

ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
154 Rep. Gr.28 - Ignition system

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise nte
eo
Passat 1997 ➤
h
Motronic
s aut
injection and ignition system (5-cyl. 4-valve) ra -
c Edition 11.2009
s
ce
e
nl
1 - Ignition coil with output
pt
du
an
stage (N70, N127, N291, N292
itte
y li
erm
and N323)
ab
ility
ot p
❑ Remove using puller -
wit
, is n
T10095 A- .
h re
hole
spec
es, in part or in w
2 - Connector
t to the co
❑ 4-pin
3 - 3-pin connector
rrectness of i
❑ Black.
l purpos
❑ For knock sensor 1 -

G61-
nf
ercia
or
4 - 3-pin connector
m
m
atio
m
❑ Brown
o
n in
or c
❑ For knock sensor 2 -
thi
te
G66-
sd
iva
o
r
rp
cu
5 - 3-pin connector
o
m
f
en
ng
t.
yi
❑ Grey
Co
Cop py
t. rig
❑ For engine speed send‐ yri
gh by
ht
er -G28- cop Vo
by lksw
cted agen
Prote
6 - 20 Nm
AG.
❑ The specified torque in‐

fluences the function of
the knock sensor.
7 - Knock sensor 1 -G61- *
❑ Gold-plated contacts on
sensor and connector.
❑ Location: cylinder block
1. Repairing ignition 155

Passat 1997 ➤
exhaust side
8 - Exhaust camshaft adjuster
❑ With sender wheel for Hall sender 2 -G163-
❑ If camshaft adjuster has been removed, check valve timing following installation: ⇒ Rep. Gr. 15; Re‐
moving and installing cylinder head; Checking valve timing .
9 - Cover
❑ Removing and installing: ⇒ Rep. Gr. 15; Removing and installing cylinder head .
10 - Seal
❑ Renew. AG. Volkswagen AG d
agen oes
11 - 10 Nm olksw not
y V gu
d b ara
se nte
12 - Hall senderth2o -G163- *
ri
eo
u ra
❑ For exhaust
ss a
camshaft. c
ce
le

un
pt
an
d
itte
y li
erm
ab
13 - Connector
ility
ot p
wit
is n
❑ Black, 3-pin.
h re
ole,
spec
❑ Mark connector before removing

14 - Hall sender -G40- * t to the co
rrectne

ss o
cial p
15 - Knock sensor 2 -G66- *

inform

mer
atio
m
❑ Fitting location: cylinder block intake side

o
n
c
i
or

thi
te
sd
va
16 - Inlet camshaft adjuster

i
o
pr
cum
r
fo
❑ With sender wheel for Hall sender -G40-

en
ng
t.
yi Co
❑ If camshaft adjuster has been removed, check valve timing following installation: ⇒ Rep. Gr. 15; Re‐
t. Cop py
moving and installing cylinder head; Checking valve timing .
rig
gh ht
pyri by
Vo
co
17 - Spark plug, 30 Nm
by lksw
cted agen
Prote AG.
❑ Remove and install with spark plug socket and extension 3122 B
❑ Type and electrode gap ⇒ page 157 , test data, spark plugs
18 - Valve timing housing
❑ For camshaft adjustment.
❑ Removing and installing: ⇒ Rep. Gr. 15; Repairing valve gear .

Passat 1997 ➤
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions. AG. Volkswagen AG d
agen oes
ksw
♦ Ensure that there is sufficient clearance to all moving by Vor
ol not
gu
hot components. rised ara
nte
ho eo
aut ra
ss c
To prevent injuries to persons and/or damage to the injection and
ce
le
un
pt
ignition system, the following must be observed:
an
d
itte
y li
rm
ab
♦ Switch off ignition before connecting or disconnecting injection
pe
ility
and ignition system wiring as well as test instrument cables.
ot
wit
, is n
h re
♦ If the engine is to be turned at starter speed without starting:
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Removing fuse 29 interrupts the voltage supply to the ignition
l purpos
coils, and removing fuse 32 interrupts the voltage supply to the

injectors.
nform
ercia

m
a
com
t
during a road test:
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1.4 Test data, spark plugs
Engine code AZX
Firing order 1-2-4-5-3
Spark plugs 1)2)3)
VW/Audi 101 000 062 AB

Manufacturer's designation PZF R5D-11
Electrode gap max. 1.1 mm
Specified torque 30 Nm
1)For current specifications plus spark plug change intervals:

⇒ Data sheets for exhaust emission test
2)Use spark spanner 3122 B and a suitable extension to remove
and install spark plugs
3) Remove ignition coils with output stage using puller -T10095 A-
only

Passat 1997 ➤
1.5 Checking Hall sender
Note
♦ Always label connectors before pulling off (risk of inter‐

change)!
♦ Only gold-plated contacts may be used when repairing con‐
tacts in Hall sender connector.
Special tools and workshop equipment required AG. Volkswagen AG d

agen oes
olksw not
V gu
♦ Test box -V.A.G 1598/31- d by ara
ise nte
or eo
h
♦ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715-aut ra
c
ss
ce
le
un
pt
an
d
♦ Current flow diagram itte
y li
erm
ab
ility
Test prerequisites
ot p
wit
is n
• Hall sender screwed on tight
h re
ole,
spec
t to the co
Test procedure
– Pull 3-pin connector off Hall sender G40 -1-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Connect multimeter to measure voltage with test leads from -
gh ht
yri by
V.A.G 1594- to contacts 1 (positive) and 3 (earth) on the Hall
op Vo
by c lksw
cted
sender connector.
agen
Prote AG.
• Specification: at least 4.5 V

Passat 1997 ➤

– Check wiring between test box and connector for open circuit
referring to current flow diagram.
AG. Volkswagen AG d
Contact 1+ socket 98 agen oes
olksw not
V gu
by ara
Contact 2+ socket 86 rised
nte
ho eo
ut
Contact 3+ socket 108 ss a ra
c
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
If no wiring fault is detected and voltage was present between
ole,
contacts 1 + 3:
spec
t to the co
– Renew Hall sender -G40-
rrectne
memory.
Test sequence for Hall sender G163 (exhaust camshaft)
ss o
cial p
f in
– Pull 3-pin connector off Hall sender G163 -2-.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Connect multimeter to measure voltage with test leads from -

V.A.G 1594- to contacts 1 (positive) and 3 (earth) on the Hall
sender connector.

Passat 1997 ➤

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Check wiring between test box and connector for open circuit
es, in part or in w
referring to current flow diagram.
t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
ti
on in
r
te o
thi
If no wiring fault is detected and voltage was present between
s
iva
do
contacts 1 + 3:
r
rp
cum
fo
– Renew Hall sender -G163- .
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
o
memory.
c by lksw
cted agen
Prote AG.
If no wiring fault is detected and no voltage was present between
contacts 1+3:
1.6 Checking ignition coils with output stage

♦ Test box -V.A.G 1598/31-

Passat 1997 ➤
Test prerequisites
Note
olkswagen AG
en AG. V
Removing the fuses interrupts the voltage supply
Vol
ksw
ag
to the injectors does
not
and the fuel pump. ed by gu
ara
ris nte
utho eo
ra
• All fuses must be OK. ss
a c
ce
le
• Engine speed sender OK, checking ⇒ page 112
un
pt
an
d
itte
y li
• Hall sender OK, checking ⇒ page 158
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
es, in part or in w
Each ignition coil is one component together with its output stage.
t to the co
Test procedure
rrectness of i
– Pull connector from ignition coil to be checked.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Using multimeter and test leads from -V.A.G 1594- , measure Prote AG.
the supply voltage between contacts 1 + 3 and 2 + 3 of dis‐
connected connector.
– Check line between 4-pin connector contact 3 and relay plate

for open circuit using current flow diagram.
– Check lines between 4-pin connector contact 1 to earth and
contact 2 to earth for open circuit using current flow diagram.
If there is no fault in the supply voltage:
Checking activation

Passat 1997 ➤
– Connect diode test lamp -V.A.G 1527- using test leads from -
V.A.G 1594- to contacts 4 + engine earth of connector pulled
off from cylinder 1.
– Operate starter and check ignition signal from engine control
unit.
• LED must flicker.
– Repeat check on connectors for cylinders 2 to 5.
AG. Volkswagen AG d
When the LED flickers and the supply voltage is OK: agen oes
olksw not
V gu
by ara
– Renew relevant ignition coil with output stage rised
nte
ho eo
ut
– Read fault memory, if necessary, repair any faults and
ss a then ra
c
ce
le
un
memory.
pt
an
d
itte
y li
If the LED does not flicker:
rm
ab
pe
ility
Checking lines
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cylinder 1 = contact 4 + socket 102 Cop py
t. rig
gh ht
yri
Cylinder 2 = contact 4 + socket 103 p by
o Vo
by c lksw
cted agen
Cylinder 3 = contact 4 + socket 110 Prote AG.
Cylinder 4 = contact 4 + socket 94

Cylinder 5 = contact 4 + socket 95
If no line fault is detected and voltage is present between contacts
1 + 3 and 2 + 3:

Passat 1997 ➤
1.7 Checking
lksw
ageknock
n AG. Volksensors
swagen AG
does
n
o ot g
yV ua
edb ran
ris tee
ho
Noteaut or
ac
ss
ce
le
♦ It is extremely important to keep to the specified torque of 20

un
pt
an
d
Nm to ensure the knock sensors perform perfectly.

itte
y li
erm
ab
♦ Only gold-plated contacts may be used when repairing the
ility
ot p
knock sensor connector contacts.
wit
is n
h re
ole,
spec
t to the co
♦ Test box -V.A.G 1598/31-
rrectne
ss
o
cial p
f inform
mer
atio
Test prerequisites
om
n
c
i
or
n
• A fault on one or both knock sensors must have been detected
thi
te
by self-diagnosis ⇒ page 8 , Reading and erasing fault mem‐

sd
iva
o
r
ory.
p
cum
r
fo
en
ng
• Coolant temperature must be at least 85°C, ⇒ display group

t.
yi Co
op
28, display zone 3 C py
t. rig
gh ht
yri by
Checking function cop Vo
by lksw
cted agen
Prote
AG.

Select function XX

– Press buttons 0 , 2 and 8 for “Display group number 28” and

1 2 3 4
Note
Knock sensor check must be carried out during a road test, as

knock sensor diagnosis is only active as of an engine speed
greater than 2000 rpm and an engine load greater than 40%.
– Carry out road test and check knock control specification on

display (display zone 4).
⇒ page 157 .
Display zones
1 2 3 4
Display group 28: Ignition, knock control

Passat 1997 ➤
Display zones
Readout xxxx rpm xxx.x % xxx.x °C Test OFF/Test ON
Syst. OK
Syst. nOK
Display Engine speed Engine load Coolant temperature Diagnostic status
shows (in steps of 40 rpm) and
diagnostic result
lkswagen AG
AG. Vo%
Range 0...6800 rpm 0.0...100.0
agen d-40.0...140.0°C
oes ---
olksw not
Specifi‐ At least 2000 rpm d by V
> 40.0 % 85.0...105.0°C
gu
ara Syst. OK
cation rise nte
tho eo
u ra
--- ss a --- --- c If specification is at‐
tained ⇒ page 164
ce
e
nl
pt
If specification is not at‐
du
an
itte
tained ⇒ page 164
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
at
om
io
n
c
in t
or
his
e

at
do
priv
Checking resistance of knock sensors

um
for
en
ng
t.
yi
Knock sensor 1 -G61-
Co
Cop py
t. rig
gh
– Disconnect brown 3-pin connector -1- from knock sensor 1 -
ht
pyri by
Vo
o
G61- .
c by lksw
cted agen
Prote AG.
– Measure resistance between contacts 1+2, 1+3 and 2+3 at

connection to knock sensor 1 -G61- .
Knock sensor 2 -G66-

Passat 1997 ➤
– Disconnect black 3-pin connector -2- from knock sensor 2 -

G66- .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Now measure
s au resistance between contacts 1+2, 1+3 and r a 2+3
c
at connection to knock sensor 2 -G66- . s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Renew knock sensor(s) ( -G61- or G66) ⇒ Item 7 (page 155)
, is n
h re
or ⇒ Item 15 (page 156) .
hole
spec
es, in part or in w
t to the co
memory.
rrectness of i
Checking lines
l purpos

nform
ercia

m
at
Knock sensor 1 -G61- :

om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Check lines between test box and brown 3-pin connector for
open circuit referring to current flow diagram.
Knock sensor 2 -G66- :

Passat 1997 ➤
wage e
– Now check lines betweenyV
olks test box and black 3-pin
s no
t connector
gu
for open circuitisereferring to current flow diagram.
d b ara
n r tee
ho
Contact 1+
sa
utsocket 107 or
ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Loosen knock sensor and tighten again to 20 Nm.
rrectness of i
– Carry out road test again and check knock control specifica‐
l purpos
tions on display.
nf
ercia
met:
orm
m
• The coolant temperature must exceed 85°C.
atio
om
n in
c
• When the temperature is reached, the operating statuses

or
thi
e
idling speed, part throttle, full throttle and overrun must be at‐
t
sd
iva
tained several times. o

r
rp
cu
o
m
f
• At full throttle, the speed must exceed 3500 rpm.

en
ng
t.
yi Co
op py
– Read control unit fault memory again. t. C rig
gh ht
pyri by
If the fault is still present:
o Vo
by c lksw
cted agen
Prote AG.
– Renew knock sensor(s) ( -G61- or -G66- )
⇒ Item 7 (page 155) or ⇒ Item 15 (page 156) .
memory.
1.8 Checking misfiring detection

Test prerequisites
• Engine mechanically OK
• No faults must be stored in fault memory ⇒ page 8 , Reading
and erasing fault memory.
Test procedure
Select function XX



Passat 1997 ➤
1 2 3 4
– Check total misfires in display zone 3.

– Also check status of misfiring detection in display zone e4.n AG. Volkswagen AG
ag does
ksw not
Vol
b Display zones
y gu
ara
ed nte
ris
1 tho2 3 eo 4
au ra
Display group 14: Ignition, misfiring detection
ss
(during vehicle operation) c
ce
e
nl
pt
Readout xxxx rpm xxx.x % xxx Activated
du
an
itte
blocked
y li
erm
ab
Display Engine speed Engine load Exhaust emission- Misfiring detection sta‐
ility
ot p
shows (in steps of 40 rpm) harming misfiring (to‐ tus
wit
, is n
tal)
h re
hole
spec
Specifi‐ 650...6500 rpm > 14.0% 0...6 Activated
es, in part or in w
cation
t to the co
--- --- If the specification is not attained ⇒ page 168 ,
evaluating display group 14
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Change to display group 15 as follows: t. Cop py
rig
gh ht
– Press button 3 (V.A.G 1551) or button ↑ (V.A.G 1552). pyri by
Vo
co lksw
by
cted agen
Indicated on display: (1…4 = display zones) Prote AG.
1 2 3 4
– Check misfires in display zones 1...3.

– Check status of misfiring detection in display zone 4.
Display zones
1 2 3 4
Display group 15: Ignition, misfiring detection (during vehicle operation)
Readout xxx xxx xxx Activated
blocked
Display Exhaust emission- Exhaust emission- Exhaust emission- Misfiring detection sta‐
shows harming misfiring, cyl. harming misfiring, cyl. harming misfiring, cyl. tus
1 2 3
Specifi‐ 0...1 0...1 0...1 Activated
cation
If specification is not attained ⇒ page 168 , display groups 15 and 16

– Change to display group 16 as follows:
Indicated on display: (1 and 4 = display zones) Read measured value block 16 ->
1 2 3 4
– Check misfires in display zones 1 and 2.

Passat 1997 ➤
– Check status of misfiring detection in display zone 4.

Display zones
1 2 3 4
Display group 16: Ignition, misfiring detection (during vehicle operation)
Readout xxx xxx Activated
blocked
Display Exhaust emission- Exhaust emission- Misfiring detection sta‐
shows harming misfiring, cyl. harming misfiring, cyl. tus
4 5
Specifi‐ 0...1 0...1 Activated
cation
. Vol wagen AG ks
If specification is not attained
swa
gen⇒AG
page 168 , display
does groups 15 and 16
olk not
yV gu
edb ara
ris nte
tho eo
– Press → button. au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Evaluating display group 14, display zone 3 - total exhaust emis‐
h re
hole
sion-harming misfires
spec
es, in part or in w
t to the co
Higher than specifi‐ ♦ Spark plug defective – Checking spark plugs
cation ⇒ page 154
rrectness of i
♦ Ignition coils with output stages defective
– Checking ignition coils with output
l purpos
stages ⇒ page 160

nf
ercia
orm
m
atio
om
n in
or c
thi
Evaluating display groups 15 and 16, display zones 1...3 - total

te
sd
a
exhaust emission-harming misfires, cyl. 1 ... cyl. 5

iv
o
r
rp
cu
o
m
f

en
ng
t.
yi Co
op py
Higher than specifi‐ ♦ Spark plug defective – Checking spark plugs
t. C rig
gh ht
cation yri
⇒ page 154
by
♦ Ignition coils with output stages defective
op Vo
by c lksw
cted agen
– Checking ignition coils with output
Prote AG.
stages ⇒ page 160


D3E80270E90-Motronic Injection and Ignition System (5-Cyl 4-Valve)

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D3E80270E90-Motronic Injection and Ignition System (5-Cyl 4-Valve)

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Service

Service Department. Technical Information

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E80270E90

1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

1.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.6 Dismantling and assembling air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.8 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.3 Checking air mass meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.4 Checking throttle valve control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.9 Checking injectors for leaks and quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.11 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.3 Checking signal from clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

5.5 Checking driving range signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

5.6 Checking kick-down point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5.7 Checking matching resistor for data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.1 Features of self-diagnosis

the engine control unit connector is pulled off or the battery is

disconnected. The contents of the fault memory will remain intact.

When the engine is subsequently started, idling may be rough for

nutes at idling speed or perform a longer road test, until the

learning process is completed. Procedure after interrupting the

voltage supply ⇒ page 139 .

General information on self-diagnosis can be found in the instruc‐

1.2 Significance of EPC warning lamp (fault

lamp for electronic power control) in

dash panel insert

1. General information on self-diagnosis 1

Fitting location of EPC warning lamp

1.3 Significance of exhaust emissions warn‐

2 Rep. Gr.01 - Self-diagnosis

Exhaust emissions warning lamp fitting location

♦ The exhaust emissions warning lamp will either flash or light

If the exhaust emissions warning lamp does not go out:

clear fault memory ⇒ page 8 , Reading and clearing fault

1.4 Technical data of self-diagnosis his

Control unit identification

1. General information on self-diagnosis 3

Functions which can be selected when using fault readers -

V.A.G 1551/1552- or -VAS 5051-

The prerequisites for selecting the desired functions can be de‐

1.5 Connecting the fault reader

4 Rep. Gr.01 - Self-diagnosis

♦ -VAS 5051- Vehicle diagnosis, testing and information system

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

and body (next to battery) OK.

– Connect diagnosis cable connector on to diagnosis connec‐

– Depending upon desired function: switch ignition on or start

Selecting operating mode:

– Press button on display for “Vehicle self-diagnosis”.

Selecting vehicle system:

– Press button “01 - Engine electronics” on display.

♦ The display fields will be displayed from top to bottom in func‐

Connecting -V.A.G 1551- :

1. General information on self-diagnosis 5

Special tools and workshop equipment required

Vehicle system tester -V.A.G 1552- can be used instead of fault

nostic connector according to fault finding programme:⇒ Cur‐

quence:⇒ Fault reader operating instructions

2 - Flash code output