Volkswagen Golf 1998 Service Manual Download Page 3

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Contents

01 - Self-diagnosis, Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Self-diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1

Self-diagnosis function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2

Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.3

Self-diagnosis - Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Locations of electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.1

Locations of electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Performing self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.1

Performing self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.2

Connecting fault reader V.A.G 1551 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . .18

3.3

List of selectable functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.4

Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3.5

Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.6

Erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.7

Initiating basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.8

Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.9

Test table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Gearbox: Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.1

Gearbox: Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.2

Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.3

Test table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

5.1

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Golf 1998 ➤

Automatic gearbox 01M self-diagnosis - Edition 10.1997

Contents

Summary of Contents for Golf 1998

Page 1: ...P DTB DTH DQE DYQ DVH DVJ DVK ECN ECK ECM ECP ECQ ECR EFB ECV ENZ ELS ELT ERX ELU ELV ELW ELY ELZ ESE EPA EPB EPC ESF ESJ FDH EPJ FCZ FDA FDB FDC FDD FDE FDF FDG EPK EPL EPD EPS EPN EPP ECT ERQ EPH EPG Edition 10 1997 Service Service Department Technical Information ...

Page 2: ... Group 01 Self diagnosis Electrical check 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 Service ...

Page 3: ...Performing self diagnosis 17 3 2 Connecting fault reader V A G 1551 and selecting functions 18 3 3 List of selectable functions 20 3 4 Interrogating fault memory 20 3 5 Fault table 21 3 6 Erasing fault memory 26 3 7 Initiating basic setting 27 3 8 Read measured value block 28 3 9 Test table 30 4 Gearbox Electrical check 39 4 1 Gearbox Electrical check 39 4 2 Electrical check 40 4 3 Test table 42 5...

Page 4: ...Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 iiContents ...

Page 5: ...s is matched to engine output Gear change map for extreme downhill stretches is matched to the braking effect of the engine Vehicles with data BUS Comprehensive information on the data bus is given in self study programme No 186 Advantages Rapid data transfer between the control units Less wiring in vehicle Safety functions of gearbox control unit The automatic control unit J217 receives informati...

Page 6: ...en circuit in wiring short circuit electrical or hydraulic components defective Wiring open circuit and or data Bus wiring short circuit Gearbox control unit fault recognition If a fault exists it is stored as a static fault If the fault no longer exists after a predetermined period or distance travelled it is considered a sporadic fault Faults which are stored in the memory as sporadically occurr...

Page 7: ... 1 Rapid data transfer Enter address word 02 gearbox electronic Compare control unit identification Interrogate fault memory 02 If No fault recognised is indica ted on the display the self diag nosis is completed Identification not OK Fault elimination according to fault table Fault finding Power transmis sion binder Renew control unit Read measured value block 08 Renew component Gearbox Perform e...

Page 8: ...ng the self diagnosis the automatic gearbox continues to operate with faults then continue fault finding using fault finding programme Fault finding binder Power transmission No 14 2 Locations of electrical electronic components 2 1 Locations of electrical electronic components 1 Automatic gearbox control unit J217 Location Page 16 Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 401...

Page 9: ...tion Fig 2 4 Valve chest Location Fig 3 The solenoid valves N88 N89 N90 N91 N92 N93 and N94 are attached to the valve body The valves are checked by self diagnosis 5 Conductor strip with integrated gearbox oil temperature sender ATF G93 Location Fig 4 Removing and installing Fig 5 G93 is checked by self diagnosis 6 Multifunction switch F125 Location and removing and installing Fig 6 F125 is checke...

Page 10: ...ttle valve potentiometer is checked by self diagnosis Location further information on potentiometer and removing and installing Fig 8 10 Solenoid for selector lever lock N110 Location and removing and installing Fig 11 The solenoid is checked by self diagnosis Can be checked in measured value block page 39 11 Selector lever position display Y5 Location Fig 7 Golf 1998 Automatic gearbox 01M self di...

Page 11: ... on kick down switch and removing and installing Fig 9 Can be checked electrically page 28 14 Brake light switch F Location and removing and installing Fig 12 Can be checked electrically page 28 15 Relay for starter lock out and reversing light J226 Location Fig 13 Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 2 1 Locations of electrical electronic components 7 ...

Page 12: ...trol unit Repair group 24 or 25 Fig 2 Diagnosis connections Location The diagnosis connection arrow is located behind the cover above the ashtray Fig 3 Valve body Location The valve body is located above oil pan Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 801 Self diagnosis Electrical check ...

Page 13: ...nductor strip The conductor strip can be changed with gearbox installed without removing the valve body Do not kink or damage the conductor strip Removing and installing conductor strip Separate connector at gearbox and remove retaining clamp drain ATF remove oil pan then remove cable guide Lever conductor strip off solenoid valve in direction of arrow with special tool 3373 If the locating points...

Page 14: ...onnet Pull connector off multi function switch Remove bolt and retainer Remove multi function switch Renew seal Installation is performed in the reverse order Tighten bolt to10 Nm Fig 7 Selector lever position display Y5 Location Selector lever position display arrow is located in combi instrument Removing and installing selector lever position display Repair group 90 Removing and installing dash ...

Page 15: ...he throttle valve potentiometer signal from the Data bus On vehicles without Data bus the signal is made available via a wire from the engine control unit The self diagnosis of the automatic gearbox only checks the signal not the potentiometer On vehicles without Data bus the wire for the signal is also checked The signal can only be read out in measured value block Read measured value block Page ...

Page 16: ...al from the Data bus On vehicles without Data bus the signal is received via a wire from the engine control unit Removing and installing kickdown switch Petrol engine On a petrol engine the accelerator cable must be removed to be able to remove and install the kick down switch then readjust cable Repair group 20 Adjusting accelerator cable Diesel engine Repair group 20 Repair group 20 Adjusting ac...

Page 17: ...01M Fig 12 Brake light switch F Location Brake light switch arrow is located on pedal cluster Removing and installing brake light switch Repair group 47 Assembly overview Pedal cluster brake pedal Assembly overview Pedal cluster brake pedal Fig 13 Relay for starter inhibitor and reversing light J226 Location Relay located on additional relay carrier under dash panel left Relay is marked with numbe...

Page 18: ...hen the gearbox is installed the sender is covered by the left assembly mounting Removing and installing road speed sender Additional information Workshop Manual Golf 1998 Automatic gearbox 01M Special tools testers and auxiliary items Workshop Manual Golf 1998 Automatic gearbox 01M Repair group 37 Removing and installing gearbox Removing and installing gearbox Obtain radio code on vehicles with c...

Page 19: ...gearbox has been supported Remove pendulum support arrows Lower gearbox approx 60 mm a Pull black connector off sender Remove bolt and pull sender 1 out Renew seal Installation is performed in the reverse order Tighten bolt to 10 Nm Tightening torques Repair group 37 Removing and installing gearbox Removing and installing gearbox Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 2 1 L...

Page 20: ...ition open bonnet Remove wiper arms and cowl panel Electrical system Repair group 94 Windscreen wiper system Removing and installing windscreen wiper system Windscreen wiper system Removing and installing windscreen wiper system Release multi pin connector then pull connector off control unit Remove screws arrows Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 1601 Self diagnosis El...

Page 21: ...s arrows then lock multi pin connector Performing self diagnosis Page 17 Initiating basic setting Page 27 3 Performing self diagnosis 3 1 Performing self diagnosis Special tools testers and auxiliary items V A G 1551 Fault reader Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 2 1 Locations of electrical electronic components 17 ...

Page 22: ...onditions Vehicle voltage supply in order Fuses No 07 11 15 and 31 in order Fuse in main fuse box 110 amps in order Earth connections for gearbox in order Selector lever in position P and handbrake applied Check earth connections for corrosion and poor contact repair if necessary Earth connecting points are located in plenum chamber and below the battery in engine compartment Check battery earth s...

Page 23: ...ntification to that shown in the example Allocation of control unit Parts catalogue 01M 927 733 BB Part No AG4 Gearbox 01M 4 speed automatic gearbox 01M 2029 EPROM Programme level Coding 00000 is not required at present WSC 00000 V A G 1551 dealership number with which the last coding was performed Indicated on display Control unit does not answer HELP By pressing the HELP key a list of possible f...

Page 24: ...ter address word 02 Gearbox electronics and advance until Select function XX appears in the display from page 18 Indicated on display Rapid data transfer HELP Select function XX Press keys 0 and 2 The function Interrogate fault memory is selected with 02 Indicated on display Rapid data transfer Q 02 Interrogate fault memory Confirm entry with key Q The number of stored faults or No fault recognise...

Page 25: ...ords below the component Output on printer V A G 1551 No fault recognised If No fault recognised appears after performing repairs the self diagnosis is completed In the event that the automatic gearbox does not operate properly despite self diagnosis carry out repairs as per fault finding programme Fault finding Power transmission binder No 14 V A G 1551 print out Page 21 Possible cause of fault R...

Page 26: ...ve Read measured value block page 28 display group number 004 Open circuit1 Short to earth1 Open circuit short to earth1 Short to positive1 00268 Wiring open or short circuit Check wiring and connections according to current flow diagram2 Solenoid valve 6 N93 Solenoid valve 6 N93 defective Read measured value block page 28 display group number 002 Open circuit1 Short to earth1 Open circuit short t...

Page 27: ... if necessary Page 14 Fig 14 Gearbox speed sender G38 No signal1 Gearbox speed sender G38 defec tive Perform electrical check from page 39 Implausible signal1 If the control unit recognises an im plausible signal the connectors for gearbox speed sender G38 and road speed sender G68 are inter changed 1 One of these displays appears in addition to relevant component V A G 1551 print out Page 21 Poss...

Page 28: ...group numbers 003 Check engine control unit Repair group 01 for relevant en gine code 00532 Battery defective Test battery voltage Repair group 27 Supply voltage Insufficient system voltage for valves Read measured value block page 28 display group number 002 V A G 1551 print out Page 21 Possible cause of fault Rectifying fault 00545 Wiring open or short circuit If additionally the faults 01312 or...

Page 29: ...f these displays appears in addition to relevant component V A G 1551 print out Page 21 Possible cause of fault Rectifying fault 00652 Gear monitoring Electrical hydraulic fault Clutch or valve chest defective Read measured value block Page 28 display group number 004 and establish by driving in which gear the fault occurs Implausible signal 00660 Open circuit in wiring Check wiring and connection...

Page 30: ...defective Fault in system ABS Check Data bus wiring and connectors accord ing to current flow diagram Check ABS control unit Repair group 01 for relevant ABS system Output on printer V A G 1551 Possible cause of fault Rectifying fault 65535 Renew control unit page 4 Control unit defective Control unit J217 defective Initiate basic setting page 27 The control unit J217 should not be renewed until t...

Page 31: ... the fault memory After interrogating and erasing the fault memory carry out a test drive and again interrogate the fault mem ory When the fault memory is interrogated the following display should appear No fault recognized 3 7 Initiating basic setting The basic setting should be initiated after performing the following repairs Exchanging engine Replacing engine control unit Altering throttle valv...

Page 32: ... diagrams Electrical fault finding and Fitting locations Golf 1998 Connect fault reader V A G 1551 and enter address word 02 Gearbox electronics and advance until Select function XX indicated on display from page 18 Indicated on display Rapid data transfer HELP Select function XX Press keys 0 and 8 The function Read measured value block is selected with 08 Indicated on display Rapid data transfer ...

Page 33: ...Gear selected Accelerator pedal value Read measured value block 4 1000 00 0 P 0 km h 004 1 2 3 4 Solenoid valves Gear selected Selector lever position Speed Read measured value block 5 40 C 0011011 0 900 rpm 005 1 2 3 4 ATF temperature Selector output Gear to be selected Engine speed Display zones 1 2 3 4 ï ï ï ï Display group No Display zone Description Read measured value block 6 006 1 2 3 4 Can...

Page 34: ... creases Initiate basic setting Page 27 Perform self diagnosis for relevant engine Full throttle min Full throttle max 3 5 V 4 680 V Adjusting renewing throttle valve potentiom eter Repair group 24 to 25 27 Vehicles with Data bus 1 Throttle valve potenti ometer signal G69 Idling 0 V When accelerating from idling to full throttle volt age figure constantly in creases Initiate basic setting Page 27 ...

Page 35: ...n switch Display 4 Kickdown Operated 1 Vehicles with acceler ator cable Check kickdown switch Perform electrical test from Page 39 Not operat ed 0 Vehicles without ac celerator cable Perform self diagno sis for relevant engine Check wiring and connectors according to current flow dia gram including Data bus wiring cont d Group No Display zone Designation Test conditions Specified readout on V A G ...

Page 36: ...age 39 3 Battery voltage Stationary min 10 8 V Check battery renew if necessary Check voltage supply to control unit J217 Perform electrical check from page 39 Cont d max 16 0 V Renew gear box control unit J217 Page 27 Group No Display zone Designation Test conditions Specified read out on V A G 1551 Rectifying fault 002 4 Road speed sender G68 Stationary min 2 20 V Check road speed sender G68 Per...

Page 37: ...d valve N91 activates the lock up clutch modulation valve and is not covered here The solenoid valves N92 and N94 are supplementary valves which affect gear shifts and are only con trolled during gear shifts and displayed in zones 5 and 6 They can show 0 or 1 depending on the driving situation At the start of a test drive the selector lever can be in position 1 Then during the drive it can be shif...

Page 38: ...ected a second mechanic is required for reading the specified values Group No Display zone Designation Test conditions Selector lever in Specified readout on V A G 1551 Rectifying fault 004 1 Solenoid valves indica ted on 31 1H 0 0 1 0 00 Solenoid valves are se lected according to driv ing condition V A G 1551 1M 0 0 1 0 00 Perform N88 Display 1 2H 0 1 1 0 00 electrical check N89 Display 2 2M 0 1 ...

Page 39: ...heck and adjust se lector lever cable Repair group 37 R R N N D D 3 3 Check multi function switch Perform electrical check from Page 39 2 2 1 1 4 Vehicle speed Speed at which vehicle is being driven1 kph The speedometer reading and readout on V A G 1551 may differ slightly 1 When driving a second mechanic is needed for reading the specified values Group No Display zone Designation Test conditions ...

Page 40: ...ector lever lock sole noid N110 Display 3 is switched on 1 Check selector lever lock solenoid N110 Per form electrical check from page 39 is switched off 0 4 switched on 1 switched off 0 Cruise control system Check wiring and con nectors according to cur rent flow diagram includ ing Data bus wiring 5 switched on 1 Check cruise control sys tem Binder Current flow di agrams Electrical fault finding ...

Page 41: ...ic is needed for reading the specified values Group No Display zone Designation Test conditions Specified readout on V A G 1551 Rectifying fault 005 4 Engine speed Driving1 with engine running rpm Perform self diagnosis for relevant engine Check wiring and connectors according to current flow dia gram including Data bus wir ing 006 Can be disregarded 1 When driving a second mechanic is needed for ...

Page 42: ... burned 1 When driving a second mechanic is needed for reading the specified values 2 The torque converter lock up clutch must be open It is open when in display zone 1 H hydraulic with slip is displayed Additionally the character or is displayed signifies that the engine speed pump speed is greater than turbine speed vehicle under traction signifies that the engine speed is less than turbine spee...

Page 43: ...mation required Workshop Manual Golf 1998 automatic gearbox 01M Binder Current flow diagrams Electrical fault finding and Fitting locations Golf 1998 Test requirements Battery voltage in order Vehicle voltage supply in order Fuses No 7 11 15 and 31 in order Fuse in main fuse box 110 amps in order Golf 1998 Automatic gearbox 01M self diagnosis Edition 10 1997 4 1 Gearbox Electrical check 39 ...

Page 44: ...ads the correct measuring range on tester must be adjusted Otherwise the electronic components can be destroyed Use the hand multimeter V A G 1526 with auxiliary cables from V A G 1594 for testing The specified values are valid for an ambient temperature from 0 C 40 C If the readings obtained differ from the specified values determine fault on the basis of the current flow diagram If the readings ...

Page 45: ...entiometer G69 earth1 10 Solenoid valve 7 N94 29 Selector lever lock solenoid N110 11 Park neutral signal 30 Vacant 12 Kickdown for air conditioner 1 31 Demand Radiator fan 13 Ignition timing influence 1 32 Vacant 14 Vacant 33 Vacant 15 Brake light switch F signal voltage 34 Vacant 16 Kickdown switch F8 35 Vacant 17 Vacant 36 Vacant 18 Multi function switch F125 pin 5 37 Vacant 19 TD revolution si...

Page 46: ...d in fault finding table and measured value block Component checked Component checked Supply voltage from control unit J217 Perform test step 1 Kick down switch F8 Perform test step 10 Brake light switch F Perform test step 2 Selector lever lock solenoid N110 Perform test step 11 Solenoid valve 1 N88 Perform test step 3 Gearbox oil temperature sender G93 ATF Perform test step 12 Solenoid valve 2 N...

Page 47: ... 4 54 67 Solenoid valve 2 Ignition switched off 55 to 65 ω 54 1 67 1 N89 Ignition switched off Switch V A G 1526 to great est ω range infinite ω Check conductor strip according to current flow dia gram 5 9 67 Solenoid valve 3 Ignition switched off 55 to 65 ω Renew conduc tor strip 9 1 67 1 N90 Ignition switched off Switch V A G 1526 to great est ω range infinite ω Removing and installing conduc to...

Page 48: ... can only be checked when switch is integra ted in accelerator cable Accelerator pedal not depressed Pull connector off switch re peat measure ment on switch Switch V A G 1526 to 200 ω range Depress accelerator as far as kickdown less than 1 5 ω Adjust acceler ator cable or re new Repair Group 20 11 23 29 Selector lever lock solenoid N110 Ignition switched off 12 to 15 ω Pull selector lever light ...

Page 49: ...end er according to cur rent flow diagram max 0 9 K ω 14 21 66 Gearbox speed sender G38 Ignition switched off Pull connector off sender repeat measurement on sender Page 14 Fig 14 Check wiring from control unit to send er according to cur rent flow diagram min 0 8 Kω Renew gearbox speed sender G38 Page 14 Fig 14 max 0 9 K ω Test step 15 Multi function switch F125 Pull connector off multi function ...

Page 50: ...om socket 23 terminal 15 on 1598 18 to socket 1 on 1598 18 earth Specification Battery voltage If the specifications are not obtained Repair wiring using current flow diagram If the specifications are obtained Check wiring further Switch off ignition Pull off relay for starter inhibitor and reversing light J226 Set multimeter to measuring range Resistance measurement 200ω Check the wiring between ...

Page 51: ...sure between sockets 23 and 63 on V A G 1598 18 Specification Infinityω Measure between socket 63 on V A G 1598 18 and contact 1 on connector Specification Less than 1 5 ω If the specifications are not obtained Repair wiring using current flow diagram If the specifications are obtained Check wiring further Measure between sockets 1 and 62 on V A G 1598 18 Specification Infinityω Measure between so...

Page 52: ...ifications are obtained Replace multi function switch Page 10 Install relay for starter inhibitor and reversing light J226 5 Definitions 5 1 Definitions These explanations refer only to this assembly group Automatic gearbox 01M self diagnosis These definitions are not necessarily generally valid ABS Anti locking brake system Further information on the ABS can be found in the relevant self study pr...

Page 53: ...Further infor mation on this can be found in Self study programme No 186 Data bus low high The voltage used to transport the data is low high Further information on this can be found in self study programme no 186 Gearbox speed sender G38 The sender records the speed of the large sun wheel in the planetary gearbox and transmits it to the automatic gearbox control unit Further information on this c...

Page 54: ...of the control unit when certain faults are recognised in order to maintain driving safety to protect the gearbox against damage and at the same time to ensure that driving characteristics are impaired as little as possible Pendulum support Designation of a part of the assembly mounting Further information on this can be found in self study pro gramme no 166 Sporadic Happens occasionally TDC signa...

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Volkswagen Golf 1998, Service Manual

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