Technical Service Information

Transcription

1 OM Technicians Guide INDE CLUTCH APPLICATI SOLENOID APPLICATI INTERNAL WIRE HARNESS & SOLENOID I.D. INTERNAL COMPENT RESISTANCE CHECK SOLENOID AIR CHECK PROCEDURE BODY BREAKDOWN SPRING SPECS CHECK BALL LOCATI COMPENT AIR CHECK PROCEDURE HYDRAULIC SCHEMATICS PARK REVERSE NEUTRAL OVERDRIVE RANGE st GEAR OVERDRIVE RANGE 2nd GEAR OVERDRIVE RANGE 3rd GEAR OVERDRIVE RANGE 4th GEAR OVERDRIVE RANGE 4th GEAR TCC MANUAL RANGE st GEAR BODY MAPPING / PASSAGE I.D. HARSH -2 UPSHIFT T.S.B DIAGNOSTIC TROUBLE S MANUAL PROCEDURE FOR RETURN TO BASIC SETUP

2 VOLKSWAGEN "0M" PRELIMINARY INFORMATI The "0M" designated transale, shown in Figure, first appeared in the 995 model year and was used in a wide variety of the Volkswagen car lines along with various engine combinations, including the 2.8L V6 engine, as shown in the chart below. The "0M" transale is a 4 speed unit, with 4th gear being overdrive, and is equipped with a clutch in the torque converter. Refer to the chart in Figure for the internal components that are applied in each of the four forward gear ranges. Notice that it has only one freewheel device for st gear. Vehicle Cabrio Beetle Golf GTI Jetta Passat "0M" MODEL USAGE CHART Years Engine Size L (L4) L (L4), 2.0L (L4),.9L Diesel L (L4), 2.0L (L4),.9L Diesel L (L4), 2.8L (V6) L (L4), 2.0L (L4),.9L Diesel, 2.8L (V6) L (L4), 2.8L (V6) The "0M" transale is totally electronic controlled and uses a Electronic Control Unit (ECU) to control shift points, apply and release of the torque converter clutch, and line pressure control. This is done using seven solenoids located on the valve body. The solenoid pattern for each gear and the description of operation is provided for you in Figure 2. Electrical signals from various sensors provide information to the ECU about vehicle speed, throttle position, engine coolant temperature, transale fluid temperature, gear range selected, converter turbine speed, engine load and engine speed. The ECU uses this information to determine the precise moment to upshift or downshift, apply or release the TCC and what fluid pressures are needed to apply the components. If for any reason the entire electronic control system of the transale becomes disabled, or the ECU detects a problem with one of the various sensors that stores a trouble code, all of the solenoids will be de-energized (Turned OFF). This "Safety Mode" operating state of the solenoids forces the transale to operate in 3rd gear when the selector lever is in the "Drive" range. We have provided you with an internal wire schematic and case connector pin identification in Figure 3, and a chart in Figure 4 to check the resistance of the solenoids and fluid temperature sensor. Refer to Figure 5 to check solenoid mechanical operation on the bench. Figures 6, 7 and 8 will provide you with eploded views of the valve body and all valve body components along with the names of each valve. The names of the valves are ATSG interpretations of the valves functions, not Volkswagens. Figure 9 will provide you with the valve body spring specifications that we observed in the valve body that was used for the illustrations, and may be different in the various models. Refer to Figures 0 and for the checkball locations in this unit and Figure 2 for air checks.

3 VOLKSWAGEN "0M" FILL WITH VW ATF (G A2) Line Pressure "CHECKING" FLUID Required Fluid Level In Pan Bottom Pan Drain Plug Bottom Pan ** RANGE Park Reverse Neutral Dr-st Dr-2nd Dr-3rd Dr-4th Man-st COMPENT APPLICATI CHART "K-" CLUT "K-2" CLUT "K-3" CLUT "B-" BRAK "B-2" BRAK Oil Level Check Plug LOW SPRG HOLD ** Converter Clutch may be on depending on throttle position and vehicle speed. CV CLUT ** ** ** Figure

4 RANGE SELECTED PARK/NEUTRAL REVERSE DRIVE - ST DRIVE - 2ND DRIVE - 3RD DRIVE - 4TH EV-2 (N89) EV-3 (N90) VOLKSWAGEN "0M" SOLENOID APPLY CHART EV- (N88) EV-2 (N89) EV-3 (N90) EV-4 (N9) * * * * EV-5 (N92) ** ** ** ** ** EV-6 (N93) *** *** *** *** *** *** EV-7 (N94) DESCRIPTI OF SOLENOID OPERATI EV- (N88) This solenoid feeds the K- clutch when it is de-energized (Off), and feeds the B- brake when it is energized (On), in Park, Neutral and 4th. This solenoid is energized in 2nd and 4th to apply the B-2 brake. This solenoid controls the K-3 clutch *EV-4 (N9) **EV-5 (N92) This solenoid is energized (On) during every shift, to drop line pressure, and orifices the apply oil to each clutch pack during the shift to provide smoother shifts. After the shift is completed, the solenoid is de-energized (Off). ***EV-6 (N93) EV-7 (N94) This PWM solenoid applies the converter clutch when it is energized (On) and is dependent on engine temp, vehicle speed and throttle position. This PWM solenoid controls main line pressure anytime the engine is running. This is a Pulse Width Modulated signal that varies with engine load and throttle position. When the solenoid is de-energized (Off) pressure goes to maimum. This solenoid controls the apply oil to the B-2 brake, to provide smoother shifts into 4th gear. It will also be energized (On) momentarily during the 2-3 shift. Figure 2

5 CASE CNECTOR PIN FUNCTIS Case Connector EV-2 (N89) EV- (N88) EV-5 (N92) EV-3 (N90) EV-4 (N9) View Looking Into Transmission Case Connector EV-7 (N94) EV-6 (N93) Transmission Fluid Temp Sensor Pin No Pin Function Voltage supply to Solenoids EV-, 2, 3, 4, 5, 7 and ATF Sensor. Voltage supply to Solenoid EV-6. Ground signal to Solenoid EV-. Ground signal to Solenoid EV-2. Ground signal to Solenoid EV-3. Ground signal to Solenoid EV-4. Ground signal to Solenoid EV-5. Ground signal to Solenoid EV-6. Ground signal to Solenoid EV-7. Fluid Temp Sensor signal return (Resistor In Ribbon). Figure 3

6 INTERNAL COMPENT RESISTANCE CHART Case Connector EV-2 (N89) EV- (N88) EV-5 (N92) EV-3 (N90) EV-4 (N9) View Looking Into Transmission Case Connector EV-7 (N94) EV-6 (N93) Transmission Fluid Temp Sensor Component Solenoid EV- (N88) Solenoid EV-2 (N89) Solenoid EV-3 (N90) Solenoid EV-4 (N9) Solenoid EV-5 (N92) Solenoid EV-6 (N93) Solenoid EV-7 (N94) TFT Sensor Pin No's. And 3 And 4 And 5 And 6 And 7 2 And 8 And 0 And 2 20 C (72 F) Ohms Ohms Ohms Ohms Ohms Ohms Ohms 90k-200k Ohms Figure 4

7 EV (N88), EV2 (N89), EV3 (N90), EV5 (N92) AND EV7 (N94) SOLENOID CHECK AND OPERATI SOLENOID OFF SOLENOID DIAMETER.785" FROM SOLENOID REGULATOR SOLENOID FROM SOLENOID REGULATOR SHIFT ORIFICE IN CASTING SHIFT ORIFICE IN CASTING WHEN THE SOLENOID IS "OFF" ORIFICED SOLENOID REGULATOR OIL WILL EHAUST OUT THE END OF THE SOLENOID WHEN THE SOLENOID IS "" ORIFICED SOLENOID REGULATOR OIL WILL BUILD UP UNDER THE SOLENOID STROKING THE THAT THE SOLENOID CTROLS EV4 (N9) AND EV6 (N93) SOLENOID CHECK AND OPERATI SOLENOID OFF SOLENOID SOLENOID DIAMETER.800" FROM SOLENOID REGULATOR FROM SOLENOID REGULATOR OR ORIFICE IN CASTING OR ORIFICE IN CASTING WHEN THE SOLENOID IS "OFF" ORIFICED SOLENOID REGULATOR OIL WILL EHAUST OUT THE SIDE OF THE SOLENOID WHEN THE SOLENOID IS "" ORIFICED SOLENOID REGULATOR OIL WILL BUILD UP UNDER THE SOLENOID STROKING THE THAT THE SOLENOID CTROLS Figure 5

8 P AUDI AND VOLKSWAGEN 0M BODY Upper valve body Spacer Plate Main Valve Body Assembly 3 Lower valve body Spacer Plate Channel Plate Figure 6

9 P P AUDI AND VOLKSWAGEN 0M BODY EPLODED VIEW LDL 0M Germany Figure 7

10 . MAIN BODY CASTING 2. EV-7 SOLENOID (N94) 3. SOLENOID RETAINING BRACKET 4. SOLENOID RETAINING BRACKET BOLTS 5. EV-6 SOLENOID (N93) 6. MANUAL ST LOCKING RETAINER (YELLOW) 7. MANUAL ST LOCKING SPRING (SEE SPRING SPEC) 8. MANUAL ST LOCKING 9. SOLENOID REGUL ATOR 0. SOLENOID REGUL ATOR SPRING (SEE SPRING SPEC). SOLENOID REGUL ATOR RETAINER 2. CVERTER REGUL ATOR 3. CVERTER REGUL ATOR SPRING (SEE SPRING SPEC) 4. CVERTER REGUL ATOR RETAINER 5. MAIN PRESSURE REGUL ATOR RETAINER (BROWN) 6. MAIN PRESSURE REG. SPRING (SEE SPRING SPEC) 7. MAIN PRESSURE REGULATOR 8. BOOST PRESSURE REGULATOR 9. BOOST PRESSURE REG. SPRING (SEE SPRING SPEC) 20. BOOST PRESSURE REGUL ATOR RETAINER (ADJUSTABLE) 2. K-3 REGULATOR RETAINING PIN 22. K-3 REGULATOR BORE PLUG 23. K-3 REGULATOR SPRING (SEE SPRING SPEC) 24. K-3 REGULATOR 25. K- REGULATOR 26. K- REGULATOR SPRING (SEE SPRING SPEC) 27. K- REGULATOR RETAINER (YELLOW) 28. MANUAL ST/K-3 LOCKOUT 29. MANUAL ST/K-3 LOCKOUT SPRING (SEE SPRING SPEC) 30. MANUAL ST/K-3 LOCKOUT RETAINER (YELLOW) 3. MANUAL 32. CVERTER CLUTCH APPLY SPRING (SEE SPRING SPEC) 33. CVERTER CLUTCH APPLY 34. CVERTER CLUTCH CTROL 36. CVERTER CLUTCH CTROL SLEEVE 37. EV-4 SOLENOID, CVERTER CLUTCH (N9) 38. EV-3 SOLENOID (N90) 39. K-3 SHIFT 40. K-3 SHIFT SPRING (SEE SPRING SPEC) 4. B - APPLY SPRING SEAT 42. B - APPLY SPRING (SEE SPRING SPEC) 43. B - APPLY 44. EV-5 SOLENOID (N92) 45. EV- SOLENOID (N88) 46. K-/B- SHIFT 47. K-/B- SHIFT SPRING (SEE SPRING SPEC) 48. B -2 SHIFT SPRING (SEE SPRING SPEC) 49. B -2 SHIFT 50. EV-2 SOLENOID (N89) 5. SOLENOID RETAINING BRACKET 52. SOLENOID RETAINING BRACKET BOLTS (6) 53. B -2 REGULATOR 54. B -2 REGULATOR SPRING (SEE SPRING SPEC) 55. B -2 REGULATOR RETAINER (BLACK) 56. K- CTROL RETAINER (BROWN) 57. K- CTROL SPRING (SEE SPRING SPEC) 58. K- CTROL TIMING TIMING SPRING (SEE SPRING SPEC) TIMING RETAINER (WHITE) Figure 8

11 VOLKSWAGEN "0M" SPRING SPECIFICATIS Main Valve Body "Back Side" "Front Side" SPRING ILLUSTRATI NO. 7: FREE LENGTH =.728" SPRING DIAMETER =.352" WIRE DIAMETER =.029" SPRING ILLUSTRATI NO. 29: FREE LENGTH =.987" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 0: FREE LENGTH =.295" SPRING DIAMETER =.454" WIRE DIAMETER = SPRING ILLUSTRATI NO. 3: FREE LENGTH =.235" SPRING DIAMETER =.330" WIRE DIAMETER =.037" SPRING ILLUSTRATI NO. 6: FREE LENGTH =.385" SPRING DIAMETER =.40" WIRE DIAMETER =.035" SPRING ILLUSTRATI NO. 9: FREE LENGTH =.460" SPRING DIAMETER =.357" WIRE DIAMETER = SPRING ILLUSTRATI NO. 23: FREE LENGTH =.090" SPRING DIAMETER =.352" WIRE DIAMETER =.029" SPRING ILLUSTRATI NO. 26: FREE LENGTH =.090" SPRING DIAMETER =.352" WIRE DIAMETER =.029" SPRING ILLUSTRATI NO. 32: FREE LENGTH =.600" SPRING DIAMETER =.29" WIRE DIAMETER =.020" SPRING ILLUSTRATI NO. 40: FREE LENGTH =.973" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 42: FREE LENGTH =.973" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 47: FREE LENGTH =.973" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 48: FREE LENGTH =.973" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 54: FREE LENGTH =.075" SPRING DIAMETER =.352" WIRE DIAMETER =.029" SPRING ILLUSTRATI NO. 57: FREE LENGTH =.968" SPRING DIAMETER =.280" WIRE DIAMETER =.027" SPRING ILLUSTRATI NO. 60: FREE LENGTH =.95" SPRING DIAMETER =.280" WIRE DIAMETER =.027" Figure 9

12 , CHANNEL PLATE UPPER SIDE CHECKBALL LOCATIS 4 6mm (.236") Diameter FREE LENGTH =.276" SPRING DIAMETER =.82" WIRE DIAMETER =.008" Figure 0

13 , 7mm (.275") Diameter With Retainer BODY UPPER SIDE CHECKBALL LOCATIS 2,, 6mm (.236") Diameter Not used in all models 3 7mm (.275") Diameter (Some Models Have Retainer), 6mm (.236") Diameter Not used in all models Retaining Pin Length =.06" Diameter =.085" NOTE: there should be only One 6mm checkball, in one location or the other. Figure

14 CASE PASSAGES FOR AIRCHECKS K3 K2 K BELLHOUSING B2 B TO MAINLINE PORT Figure 2

15 from cooler to cooler COOLER OUTPUT SUCTI LUBRICATI.044" N89-EV2 "OFF" N88-EV "".044" N92-EV5 "OFF" N90-EV3 "" N9-EV4 "OFF" MAIN LINE PORT 2 3 D N R P 3 B2 BRAKE K2 CLUTCH on Torque Converter Clutch off.063".057" B2 SHIFT K/B SHIFT B APPLY K3 SHIFT CVERTER CLUTCH APPLY.046" MANUAL K3/MANUAL "" LOCKING K CLUTCH K3 CLUTCH B BRAKE.056".048" B2-BRAKE REG. K CTROL 2 N94-EV7 "OFF" N93-EV6 "MOD" SOLENOID APPLICATI N88-EV OFF N89-EV2 N90-EV3 OFF N9-EV4 OFF N92-EV5 MOD* N93-EV6 OFF N94-EV7.056" 2-3 TIMING K CLUTCH REG. K3 CLUTCH REG..047".045" BOOST REG. MAIN REG. CVERTOR REG..038".058".098" MANUAL "" LOCKING.078" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE.079" SOLENOID REG. K CLUTCH PREFILL (0 psi.) CNECTED CIRCUIT 4.063".058".058".078".079" "0M" PARK POSITI FILTER SUMP

16 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI N89-EV2 "OFF" N88-EV "OFF".044" N92-EV5 "*" N90-EV3 "" N9-EV4 "OFF" MAIN LINE PORT 2 3 D N R P 3 B2 BRAKE K2 CLUTCH on Torque Converter Clutch off.063".057" B2 SHIFT K/B SHIFT B APPLY K3 SHIFT CVERTER CLUTCH APPLY.046" MANUAL K3/MANUAL "" LOCKING K CLUTCH K3 CLUTCH B BRAKE.056" B2-BRAKE REG. K CTROL 2 N94-EV7 "OFF" N93-EV6 "MOD" SOLENOID APPLICATI OFF N88-EV OFF N89-EV2 N90-EV3 OFF N9-EV4 OFF* N92-EV5 MOD* N93-EV6 OFF N94-EV7.056" 2-3 TIMING K CLUTCH REG. K3 CLUTCH REG..047".045" BOOST REG. MAIN REG. CVERTOR REG..038".058".098" MANUAL "" LOCKING.078" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE 4.079".063".058".058" SOLENOID REG..078".079" K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT "0M" REVERSE RANGE FILTER SUMP

17 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI N89-EV2 "OFF" N88-EV "".044" N92-EV5 "OFF" N90-EV3 "" N9-EV4 "OFF" MAIN LINE PORT 2 3 D N R P 3 B2 BRAKE K2 CLUTCH on Torque Converter Clutch off.063".057" B2 SHIFT K/B SHIFT B APPLY K3 SHIFT CVERTER CLUTCH APPLY.046" MANUAL K3/MANUAL "" LOCKING K CLUTCH K3 CLUTCH B BRAKE.048" B2-BRAKE REG. 2 N94-EV7 "OFF" SOLENOID APPLICATI N88-EV OFF N89-EV2.056" K CTROL N93-EV6 "MOD" OFF OFF MOD* OFF N90-EV3 N9-EV4 N92-EV5 N93-EV6 N94-EV7.056" 2-3 TIMING K CLUTCH REG. K3 CLUTCH REG..047".045" BOOST REG. MAIN REG. CVERTOR REG..038".058".098" MANUAL "" LOCKING.078" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE.079" SOLENOID REG. K CLUTCH PREFILL (psi.) CNECTED CIRCUIT 4.063".058".058".078".079" "0M" NEUTRAL RANGE FILTER SUMP

18 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "OFF" B2 SHIFT N88-EV "OFF" K/B SHIFT.044" N92-EV5 "*" B APPLY N90-EV3 "" N9-EV4 "OFF" K3 SHIFT CVERTER CLUTCH APPLY.046" MAIN LINE PORT MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048".056" B2-BRAKE REG. K CTROL 2 N94-EV7 "OFF" N93-EV6 "MOD" SOLENOID APPLICATI OFF N88-EV OFF N89-EV2 N90-EV3 OFF N9-EV4 * N92-EV5 MOD* N93-EV6 OFF N94-EV7.056" 2-3 TIMING 4 K CLUTCH REG. K3 CLUTCH REG..047".045".079" BOOST REG..063".058" MAIN REG..058" CVERTOR REG..038".058".098" FILTER MANUAL "" LOCKING SOLENOID REG..078".078".079" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (psi.) CNECTED CIRCUIT "0M" OVERDRIVE RANGE st GEAR SUMP

19 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "" B2 SHIFT N88-EV "OFF" K/B SHIFT.044" N92-EV5 "*" B APPLY N90-EV3 "" N9-EV4 "OFF" K3 SHIFT CVERTER CLUTCH APPLY.046" MAIN LINE PORT MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048" B2-BRAKE REG. 2 N94-EV7 "OFF" SOLENOID APPLICATI OFF N88-EV N89-EV2.056" K CTROL N93-EV6 "MOD" OFF * MOD* OFF N90-EV3 N9-EV4 N92-EV5 N93-EV6 N94-EV7.056" 2-3 TIMING 4 K CLUTCH REG. K3 CLUTCH REG..047".045".079" BOOST REG..063".058" MAIN REG..058" CVERTOR REG..038".058".098" FILTER MANUAL "" LOCKING SOLENOID REG..078".078".079" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT "0M" OVERDRIVE RANGE 2nd GEAR SUMP

20 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "OFF" B2 SHIFT N88-3V "OFF" K/B SHIFT.044" N92-EV5 "*" B APPLY N90-EV3 "OFF" N9-EV4 "OFF" K3 SHIFT CVERTER CLUTCH APPLY.046" MAIN LINE PORT MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048".056" B2-BRAKE REG. K CTROL 2 N94-EV7 "" N93-EV6 "MOD" SOLENOID APPLICATI OFF N88-EV OFF N89-EV2 OFF N90-EV3 OFF N9-EV4 * N92-EV5 MOD* N93-EV6 N94-EV7.056" 2-3 TIMING 4 K CLUTCH REG. K3 CLUTCH REG..047".045".079" BOOST REG..063".058" MAIN REG..058" CVERTOR REG..038".058".098" MANUAL "" LOCKING SOLENOID REG..078".078".079" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT "0M" FILTER OVERDRIVE RANGE 3rd GEAR SUMP

21 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "" B2 SHIFT N88-EV "" K/B SHIFT.044" N92-EV5 "*" N90-EV3 "OFF" N9-EV4 "OFF" B APPLY K3 SHIFT CVERTER CLUTCH APPLY.046" MAIN LINE PORT MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048" B2-BRAKE REG. 2 N94-EV7 "" SOLENOID APPLICATI N88-EV N89-EV2 OFF N90-EV3.056".056" K CTROL 2-3 TIMING K CLUTCH REG. K3 CLUTCH REG..047".045" BOOST REG. MAIN REG. CVERTOR REG..038".058".098" MANUAL "" LOCKING.078" N93-EV6 "MOD" OFF * MOD* LEGEND N9-EV4 N92-EV5 N93-EV6 N94-EV7 MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE 4.079".063".058".058" FILTER SOLENOID REG..078".079" K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT "0M" OVERDRIVE RANGE 4th GEAR SUMP

22 to cooler from cooler COOLER.044" OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "" B2 SHIFT N88-EV "" K/B SHIFT.044" N92-EV5 "*" N90-EV3 "OFF" N9-EV4 "" B APPLY K3 SHIFT CVERTER CLUTCH APPLY.046" MAIN LINE PORT MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048" B2-BRAKE REG. 2 N94-EV7 "" SOLENOID APPLICATI N88-EV N89-EV2 OFF N90-EV3.056".056" K CTROL 2-3 TIMING K CLUTCH REG. K3 CLUTCH REG..047".045" BOOST REG. MAIN REG. CVERTOR REG..038".058".098" MANUAL "" LOCKING.078" N93-EV6 "MOD" * MOD* LEGEND N9-EV4 N92-EV5 N93-EV6 N94-EV7 MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE.079" SOLENOID REG. K CLUTCH PREFILL (0psi.) CVERTER RELEASE (TCC ) 4.063".058".058".078".079" CNECTED CIRCUIT "0M" FILTER OVERDRIVE RANGE 4th GEAR TCC "" SUMP

23 to cooler from cooler COOLER.044" OUTPUT SUCTI MAIN LINE PORT B2 BRAKE LUBRICATI on Torque Converter Clutch off.063".057" N89-EV2 "OFF" B2 SHIFT N88-EV "OFF" K/B SHIFT.044" N92-EV5 "*" B APPLY N90-EV3 "" N9-EV4 "OFF" K3 SHIFT CVERTER CLUTCH APPLY.046" MANUAL 2 3 D N R P 3 K3/MANUAL "" LOCKING K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE.048".056" B2-BRAKE REG. K CTROL 2 N94-EV7 "OFF" N93-EV6 "MOD" SOLENOID APPLICATI OFF N88-EV OFF N89-EV2 N90-EV3 OFF N9-EV4 * N92-EV5 MOD* N93-EV6 OFF N94-EV7.056" 2-3 TIMING 4 K CLUTCH REG. K3 CLUTCH REG..047".045".079" BOOST REG..063".058" MAIN REG..058" CVERTOR REG..038".058".098" FILTER MANUAL "" LOCKING SOLENOID REG..078".078".079" MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (psi.) CNECTED CIRCUIT "0M" MANUAL "" RANGE st GEAR SUMP

24 BODY MAPPING PARTIAL HYDRAULIC SCHEMATIC FOR K CLUTCH REGULATOR K CLUTCH REG. 325U 330L 329U 33L 329U 330U 328U 330L.063" 330L UPPER BODY 300U SERIES 338U 334U 302U 325U 328U 32U 38U 336U 336U* 335U 323U 322U 3U 320U 326U 32U 327U 337U 39U 324U 33U 330U 329U 35U 305U 308U 305U* 34U 340U 309U 37U 303U 339U 30U 338U 30U 36U 325U 333U 334U 332U 307U 304U 302U 328U 34U 306U 33U 39U 324U 33U 330U 329U 342U HOW TO USE THIS MANUAL: All castings and spacer plates have been numbered so they can be identified in an oil circuit diagram. Eample: 329U passage is located in the Upper valve body (300U series). This passage can now be located in the partial oil circuit diagram shown above. Spacer plate orifice sizes and locations are also identified in the oil circuit diagram labled Valve body Mapping.

25 P AUDI AND VOLKSWAGEN 0M BODY CASE PASSAGES - 00 SERIES Upper valve body Spacer Plate UPPER SPACER PLATE 200 SERIES Main Valve Body Assembly UPPER BODY 300U SERIES LOWER BODY 300L SERIES 3 Lower valve body Spacer Plate LOWER SPACER PLATE 400 SERIES Channel Plate UPPER CHANNEL PLATE 500U SERIES LOWER CHANNEL PLATE 500L SERIES

26 500L SERIES LOWER CHANNEL PLATE L 50L 507L 95 52L 50L 504L 5L 0 M 505L Ger m a ny 503L 503L 506L 50L 502L 53L

27 , 500U SERIES UPPER CHANNEL PLATE 508U 526U 58U 528U 5U 56U 52U 57U 523U 55U 53U 527U 507U 505U 524U 525U 59U 54U 509U 506U 503U 50U 522U 502U 52U 520U 504U 50U 4 6mm

28 400 SERIES LOWER SPACER PLATE 42 I.D

29 300L SERIES LOWER BODY 30L 30L2 30L3 30L4 30L5 344L 36L 34L 39L 348L 346L 340L 3L 336L 339L 332L 338L 328L 349L 329L 302L (slot**) 325L 327L 302L(slot*) 38L 343L 342L 302L 326L 305L 34L 347L 337L 309L 35L 308L 324L 320L 323L 302L (slot) 345L 37L 322L 330L 32L 334L 335L 333L 304L 30L 306L 32L 32L 307L 33L 303L 33L

30 ,, 300U SERIES UPPER BODY 2 7mm With retainer 3U 32U 38U 336U 336U* 335U 323U 322U 320U 326U 32U 327U 337U 6mm Not used in all models, 3, 7mm (May have retainer on some models) 305U 308U 35U 307U 34U 305U* 34U 340U 309U 37U 303U 339U 30U 304U 33U 306U 342U 30U 36U 338U 302U 39U 325U 324U 33U 332U 333U 334U 328U 330U 329U 6mm Not used in all models NOTE: there should be only 6mm. checkball, in one or the other location.

31 200 SERIES UPPER SPACER PLATE DIMPLE DIMPLE DIMPLE DIMPLE

32 00 SERIES CASE PASSAGES BELLHOUSING PASSAGE CLOSED (COULD BE A TEST PORT FOR N93-EV6 FROM INSIDE THE PAN) TO MAINLINE PORT

33 to cooler from cooler COOLER MAIN LINE PORT OUTPUT SUCTI LUBRICATI on Torque Converter Clutch off 34L.056" 32L.056" " 525U 524U 509U 507U 328U.063" 332U 347L 347L 332L 333U 339L 338L 325U.057" 328U 334U 337L 309L 309L 335L " 33L B2-BRAKE REG. K CTROL 2-3 TIMING U ".045" 3U U 333L 30L U N89-EV2 "OFF" 320U 327U 332U B2 SHIFT K CLUTCH REG. 325U 330L 329U U 330U 328U 33L 330L.063" 330L 30L 39L 336L K3 CLUTCH REG. 325U 324U 33U 33U 334L 332L 333L 333L " 522U 52U 520U 326U 326U 32U 36U 429 N88-EV "" K/B SHIFT 36U 332L 36L L2 36L 38L 349L 327L 2 57U BOOST REG. 309U 338U 303U 302U.079" N92-EV5 "OFF" 32U 322U 325U B APPLY U 35L 30L3 348L 302L (slot**) 329L U 58U 304U (slot) 340U 38L MAIN REG. 340U.038" 30U 304U 33U 303U.058" N90-EV3 "" N9-EV4 "OFF" 320U 323U K3 SHIFT 302L (slot) U 320L.058" 304L 30L.058" 30L4 346L 337L 325L 328L 336U 335U 306U 336U* CVERTER CLUTCH APPLY 339U 34U 33U 337U CVERTOR REG. 34L 340L 343L 342L 344L 306L.098" 303L 30L " 50U 502U 528U 527U 526U 503U 5U 505U 38U 305U 37U 305U 302L (slot*) (slot*) MANUAL "" LOCKING 345L.078" SOLENOID REG. 30U 308L 406 MANUAL 305L.078" U 309U 304U 30L.079" D N R P 36L 302L 324L 323L 322L 32L 32U 35U 307U 307L 3L 305L 305L 37L 39U 3 32L 324L 35U 33L 38U 320U 34U K3/MANUAL "" LOCKING N94-EV7 "OFF" N93-EV6 "MOD" U 508U 50U 53U U 55U 326L B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE SOLENOID APPLICATI OFF OFF OFF MOD* OFF LEGEND N88-EV N89-EV2 N90-EV3 N9-EV4 N92-EV5 N93-EV6 N94-EV7 MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF MAIN LINE PRESSURE SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT "0M" PARK POSITI BODY MAPPING 509L 503L 52L 53L 507L 503L 504L 508L 50L FILTER SUMP 5L 50L 502L 506L 505L

34 VOLKSWAGEN / AUDI UNCTROLLABLE HARSH -2 UPSHIFT COMPLAINT: Before or after overhaul, vehicles equipped with 0M, 0N and 0P transales, may ehibit a harsh -2 upshift along with firmer than normal engagements as well as firm upshifts to 3rd and 4th. CAUSE: The cause may be,. Erratic or high line pressure. 2. An electrical malfunction in the EV5 solenoid electrical circuit. 3. A Hydraulic malfunction with EV5 solenoid. (NOTE: The EV5 solenoid is grounded on each engagement and each upshift and downshift which helps control Clutch apply Pressure for smooth engagements as shown in Figures 3 and 4.) CORRECTI: To correct this condition:. Connect a pressure gage to the line pressure port as shown in Figure. Line pressure should indicate 60 psi. in the Drive position at idle and should increase to psi. at stall. Line pressure should cut back to between psi. on each shift. If Line pressure does not cut back on each shift, or is at psi. at all times, or is erratic on the gage, replace the EV6 solenoid and check the Boost Regulator and Main Regulator valve to ensure they are not stuck. Refer to Figure 2 for a description of how EV6 Solenoid operates. 2. Refer to Figure 5 and locate terminal 7 at harness connector. Back probe that terminal to verify that the computer is grounding EV5 during the -2 upshift. If the computer is not grounding that terminal, go to STEP A. If the Computer is grounding that terminal go to STEP B. STEP A. Connect a scan tool to the diagnostic connector and check to see if the TCM has set a trouble code (VAG) or a P0773 which are EV5 solenoid circuit faults. Repair the EV5 Solenoid circuit as needed. If the TCM has no trouble codes set and does not ground EV5 Solenoid during the -2 shift, the TCM may be faulty. STEP B. Go to Correction number Remove EV5 Solenoid from its bore. Ensure that the B Apply valve, which is located below the solenoid, is not sticking in it s bore. Air check EV5 solenoid and ensure it s proper operation as shown in Figure 6. If EV5 Solenoid does not close consistently replace as needed.

35 LINE PRESSURE CHECK Line Pressure LINE PRESSURE SHOULD INDICATE 60psi. AT IDLE IN DRIVE LINE PRESSURE WILL INCREASE TO BETWEEN 20-50psi. AND SHOULD CUT BACK TO EACH SHIFT Figure

36 N93-EV6 "MOD" "0M" N93-EV6 OPERATI FROM MANUAL FROM K/B SHIFT FROM PUMP OUTPUT FROM MANUAL MAIN REG. FILTER SUMP.044 BOOST REG..058".038".045" SOLENOID REG..079".058".058" N93-EV6, WHEN MODULATING, STROKES THE BOOST REGULATOR AGAINST ITS SPRING, REDUCING THE AMOUNT OF BOOST PRESSURE THE SPRING SIDE OF THE MAIN REGULATOR. Figure 2

37 B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE "0M" OVERDRIVE RANGE st to 2nd GEAR TRANSITI N92-EV5 "*".044" SOLENOID FEED SOLENOID APPLICATI OFF N88-EV N89-EV2 N90-EV3 OFF N9-EV4 * N92-EV5 MOD* N93-EV6 OFF N94-EV7 MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE FROM MANUAL TO K/B SHIFT TO K3/MANUAL LOCKING B APPLY.063" SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT.057" B2-BRAKE REG..048" FROM K CTROL FROM 2-3 TIMING N92-EV5 IS "" WHEN THE GEAR CHANGE IS COMMANDED K CLUTCH REG. K3 CLUTCH REG..047" SUMMARY: THIS CNECTS LINE PRESSURE FROM THE MANUAL TO THE ST LAND OF THE B2 REGULATOR CTROLS THE APPLY RATE OF THE B2 CLUTCH TO 2-3 TIMING Figure 3

38 B2 BRAKE K2 CLUTCH K CLUTCH K3 CLUTCH B BRAKE "0M" OVERDRIVE RANGE 2nd GEAR APPLICATI N92-EV5 "OFF.044" SOLENOID FEED SOLENOID APPLICATI OFF N88-EV N89-EV2 N90-EV3 OFF N9-EV4 * N92-EV5 MOD* N93-EV6 OFF N94-EV7 MOD* = MODULATING * = BRIEFLY DURING THE ENGAGEMENT THEN OFF LEGEND MAIN LINE PRESSURE FROM MANUAL TO K/B SHIFT TO K3/MANUAL LOCKING B APPLY.063" SOLENOID REG.PRESSURE PUMP SUCTI CVERTER REG.PRESSURE LUBE PRESSURE K CLUTCH PREFILL (0psi.) CNECTED CIRCUIT.057" B2-BRAKE REG..048" FROM K CTROL FROM 2-3 TIMING N92-EV5 IS "OFF" WHEN THE GEAR CHANGE IS COMPLETED K CLUTCH REG. K3 CLUTCH REG..047" SUMMARY: THE B2 CLUTCH IS APPLIED WITH LINE PRESSURE TO 2-3 TIMING Figure 4

39 CASE CNECTOR PIN FUNCTIS Case Connector EV-2 (N89) EV- (N88) EV-5 (N92) EV-3 (N90) EV-4 (N9) View Looking Into Transmission Case Connector EV-7 (N94) EV-6 (N93) Transmission Fluid Temp Sensor Pin No Pin Function Voltage supply to Solenoids EV-, 2, 3, 4, 5, 7 and ATF Sensor. Voltage supply to Solenoid EV-6. Ground signal to Solenoid EV-. Ground signal to Solenoid EV-2. Ground signal to Solenoid EV-3. Ground signal to Solenoid EV-4. Ground signal to Solenoid EV-5. Ground signal to Solenoid EV-6. Ground signal to Solenoid EV-7. Fluid Temp Sensor signal return (Resistor In Ribbon). BACK PROBE THIS TERMINAL Figure 5

40 EV (N88), EV2 (N89), EV3 (N90), EV5 (N92) AND EV7 (N94) SOLENOID CHECK AND OPERATI SOLENOID OFF SOLENOID DIAMETER.785" FROM SOLENOID REGULATOR SOLENOID FROM SOLENOID REGULATOR SHIFT ORIFICE IN CASTING SHIFT ORIFICE IN CASTING WHEN THE SOLENOID IS "OFF" ORIFICED SOLENOID REGULATOR OIL WILL EHAUST OUT THE END OF THE SOLENOID WHEN THE SOLENOID IS "" ORIFICED SOLENOID REGULATOR OIL WILL BUILD UP UNDER THE SOLENOID STROKING THE THAT THE SOLENOID CTROLS EV4 (N9) AND EV6 (N93) SOLENOID CHECK AND OPERATI SOLENOID OFF SOLENOID SOLENOID DIAMETER.800" FROM SOLENOID REGULATOR FROM SOLENOID REGULATOR OR ORIFICE IN CASTING OR ORIFICE IN CASTING WHEN THE SOLENOID IS "OFF" ORIFICED SOLENOID REGULATOR OIL WILL EHAUST OUT THE SIDE OF THE SOLENOID WHEN THE SOLENOID IS "" ORIFICED SOLENOID REGULATOR OIL WILL BUILD UP UNDER THE SOLENOID STROKING THE THAT THE SOLENOID CTROLS Figure 6

41 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II DEFINITIS COMPLAINT: CAUSE: CORRECTI: When a VW/Audi vehicle is ehibiting a symptom or is in fail-safe, the technician, in many cases, is unable to communicate with the on-board diagnostics in order to retrieve codes. The lack of aftermarket equipment, previously available to the technician, to allow access to vehicle on-board diagnostics such as, code retrieval, data lists and basic setting resets. With the OBD-II mandate beginning in 996, it is possible to retrieve codes using the Generic OBD-II part of your scan tool. This will also allow access to the "freeze frame" and "pending code" categories which are diagnostic aids to help the technician retrieve codes and data. There have also been recent developments which have made available, diagnostic tools which can communicate with VW/Audi vehicle modules which include pre-obd-ii diagnostics for codes and data. Use the illustrations in figures and 2 for diagnostic connector locations in all Volkswagen/Audi models equipped with 096, 097, 098, 0M, 0N and 0P transmissions. Use the code definition charts in figures 3 to 2 for ECM codes for gasoline engine equipped vehicles. Use the code definition charts in figures 3 to 5 for ECM codes for diesel engine equipped vehicles. Use the code definition charts in figures 6 and 7 for TCM codes.

42 rpm 00 UNLEADED FUEL F VOLKSWAGEN/AUDI 0M/0N/0P VOLKSWAGEN DIAGNOSTIC CNECTOR LOCATIS 994 PASSAT, CORRADO PASSAT NET TO STEERING COLUMN IN DASH BELOW TACHOMETER, FORWARD OF THE IGNITI SWITCH REMOVE POP OFF PANEL OBD-II 6 PIN CNECTOR 993 JETTA, GOLF CORRADO & CABRIOLET BEHIND POP OUT PANEL BELOW HVAC CTROLS (BLACK SINGLE CNECTOR) (WHITE SINGLE CNECTOR) mph JETTA & GOLF JETTA, GOLF & CABRIO REMOVE ASHTRAY & SLIDE PANEL TO THE LEFT BELOW HVAC CTROLS OBD-II 6 PIN CNECTOR ALL MODELS 993 PASSAT UNDER SHIFT LEVER INDICATOR PANEL INSIDE CENTER CSOLE (BLACK SINGLE CNECTOR) (WHITE SINGLE CNECTOR) NEW BEETLE BELOW CENTER OF DASH, FORWARD OF THE SHIFT LEVER OBD-II 6 PIN CNECTOR CABRIO, GOLF, JETTA & GTI REMOVE COVER BELOW RADIO FORWARD OF THE SHIFT LEVER OBD-II 6 PIN CNECTOR Figure

43 rpm 00 UNLEADED FUEL F VOLKSWAGEN/AUDI 0M/0N/0P AUDI & EUROVAN DIAGNOSTIC CNECTOR LOCATIS EUROVANS REMOVE STORAGE COMPARTMENT IN FRT OF RELAY PLATE (BLACK SINGLE CNECTOR) (WHITE SINGLE CNECTOR) AUDI AUDI AUDI AUDI CABRIOLET DRIVER SIDE OF ENGINE BAY, REMOVE AUILIARY RELAY BO COVER. CNECT TO BLACK AND WHITE CNECTORS mph AUDI CABRIOLET UNDER DRIVER SIDE DASH BELOW STEERING COLUMN OBD-II 6 PIN CNECTOR 996 AUDI CABRIOLET REMOVE CENTER CSOLE ASHTRAY OBD-II 6 PIN CSOLE Figure 2

44 OBD-II P002 P VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS MAF or VAF Sensor MAF or VAF Sensor P006 P007 N/A 649 MAP or BARO Pressure Sensor BARO Pressure Sensor Circuit Low P MAP or BARO Pressure Sensor P02 P IAT Sensor Circuit Input Out Of Range IAT Sensor Circuit Input Out Of Range P06 P ECT Sensor Circuit Input Out Of Range ECT Sensor Circuit Input Low P08 P020 P02 P ECT Sensor Circuit Input Out Of Range Throttle Position Sensor "A" Circuit Malfunction Throttle/Pedal Position Sensor Circuit Fault Throttle/Pedal Position Sensor Circuit Input Low P Throttle/Pedal Position Sensor Circuit Fault P025 P030 P03 P032 P033 P034 P Insufficient ECT Temperature For Closed Loop Fuel Control 6509 Heated Oygen Sensor - Bank Sensor Circuit Fault 655 Heated Oygen Sensor - Bank Sensor Input Low 656 Heated Oygen Sensor - Bank Sensor Input High 657 Oygen Sensor - Bank Sensor Slow Response 658 Oygen Sensor - Bank Sensor No Activity 659 Oygen Sensor Heater - Bank Sensor Malfunction P036 P037 P038 P Oygen Sensor - Bank Sensor 2 Circuit Fault Oygen Sensor - Bank Sensor 2 Input Low Oygen Sensor - Bank Sensor 2 Input High Oygen Sensor - Bank Sensor 2 Slow Response Figure 3

45 OBD-II P038 P039 P040 P04 P050 P05 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 6522 Oygen Sensor - Bank Sensor 2 Input High 6523 Oygen Sensor - Bank Sensor 2 Slow Response 6524 Oygen Sensor - Bank Sensor 2 No Activity 6525 Oygen Sensor - Bank Sensor 2 Heater Circuit Malfunction 6534 Oygen Sensor - Bank 2 Sensor Circuit Malfunction 6535 Oygen Sensor - Bank 2 Sensor Input Low P052 P053 P054 P056 P057 P058 P060 P070 P07 P072 P0300 P030 P0302 P0303 P0304 P * Oygen Sensor - Bank 2 Sensor Input High Oygen Sensor - Bank 2 Sensor No Activity Oygen Sensor - Bank 2 Sensor Slow Response Oygen Sensor - Bank 2 Sensor 2 Circuit Malfunction Oygen Sensor - Bank 2 Sensor 2 Input Low Oygen Sensor - Bank 2 Sensor 2 Input High Oygen Sensor - Bank 2 Sensor 2 No Activity Fuel Trim Malfunction System Too Lean Bank System Too Rich Bank Random Misfire Detected Cylinder No. Misfire Detected Cylinder No. 2 Misfire Detected Cylinder No. 3 Misfire Detected Cylinder No. 4 Misfire Detected Cylinder No. 5 Misfire Detected P Cylinder No. 6 Misfire Detected P Engine Speed Sensor Circuit Fault P Engine Speed Sensor No Signal P Knock Sensor No. Circuit Input Low *2.8L VR6, Engine Code AFP, GTI and Jetta Only Figure 4

46 OBD-II P0328 P0332 P0333 P034 P0342 P0343 ECM VAG DEFINITIS 672 Knock Sensor No. Circuit Input High Camshaft Position Sensor Circuit Fault VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES Knock Sensor No. Circuit Input Low Knock Sensor No. 2 Circuit Input High Camshaft Position Sensor Circuit Input Low Camshaft Position Sensor Circuit Input High P04 P0420 P0422 P0432 P0440 P044 P0442 P0445 P0455 P050 P0506 P0507 P050 P0560 P0562 P Main Catalyst Efficiency Below Threshold Tank Vent System Malfunction 6825 EVAP Emission System Incorrect Purge Flow 6826 * Vehicle Speed Sensor Circuit Fault 6890 Idle RPM Too Low Closed Throttle Position Switch Malfunction 6944 System Voltage Malfunction P Cruise/Brake Switch Circuit Malfunction P ECM Check Sum Error P P ECM RAM Error *2.8L V6, Engine Code AHA, Passat Only Secondary Air Injection System Incorrect Flow Detected Main Catalyst Efficiency Below Threshold Bank Main Catalyst Efficiency Below Threshold Bank 2 EVAP Emission System Small Leak Detected EVAP Emission System Large Leak Detected EVAP Emission System Large Leak Detected Idle RPM Too High System Voltage Too Low System Voltage Too High ECM KAM Error Figure 5

47 OBD-II P0605 P0707 P0708 P075 P0722 P0725 ECM VAG 6989 ECM ROM Error DEFINITIS 7099 Turbine Speed Sensor Circuit Malfunction VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES Transmission Range Sensor Circuit Input Low Transmission Range Sensor Circuit Input High Output Speed Sensor Circuit No Signal Engine Speed Circuit Malfunction P0748 P0753 P0758 P0763 P0768 P0773 P02 P05 P07 P0 P3 P5 P6 P7 P8 P Pressure Control Solenoid Electrical Fault Shift Solenoid "A" Electrical Fault Shift Solenoid "B" Electrical Fault Shift Solenoid "C" Electrical Fault Shift Solenoid "D" Electrical Fault Shift Solenoid "E" Electrical Fault Heated Oygen Sensor - Bank Sensor Short To Voltage Heated Oygen Sensor - Bank Sensor Heater Short To Voltage Heated Oygen Sensor - Bank 2 Sensor Heater Short To Voltage Heated Oygen Sensor - Bank 2 Sensor 2 Heater Short To Voltage Heated Oygen Sensor Heater Circuit Resistance Too High Heated Oygen Sensor Heater Circuit Short To Ground Heated Oygen Sensor Heater Circuit Open Heated Oygen Sensor 2 Heater Circuit Short To Ground Heated Oygen Sensor 2 Heater Circuit Open Long Term Fuel Trim Too Rich Bank P Long Term Fuel Trim Too Lean Bank P Long Term Fuel Trim Too Rich Bank 2 P Long Term Fuel Trim Too Lean Bank 2 P Long Term Fuel Trim Too Lean Bank Figure 6

48 OBD-II P37 P38 P39 P4 P7 P72 ECM VAG DEFINITIS 7545 Long Term Fuel Trim Too Rich Bank Load Calculation Cross Check Performance VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES Long Term Fuel Trim Too Lean Bank 2 Long Term Fuel Trim Too Rich Bank 2 Throttle Position Potentiometer Circuit Fault Throttle Position Potentiometer Circuit Too Low P73 P76 P77 P96 P97 P98 P99 P23 P24 P25 P26 P27 P28 P225 P226 P Throttle Position Potentiometer Circuit Too High Heated Oygen Sensor 2 Correction Limit Attained Heated Oygen Sensor Correction Behind Catalyst Limit Attained Bank 2 Heated Oygen Sensor Circuit Malfunction Heated Oygen Sensor Bank 2 Heater Circuit Electrical Fault Heated Oygen Sensor 2 Bank Heater Circuit Electrical Fault Heated Oygen Sensor - Bank 2 Sensor 2 Heater Circuit Electrical Fault Cylinder No. Fuel Injector Circuit Short To Voltage Cylinder No. 2 Fuel Injector Circuit Short To Voltage Cylinder No. 3 Fuel Injector Circuit Short To Voltage Cylinder No. 4 Fuel Injector Circuit Short To Voltage Cylinder No. 5 Fuel Injector Circuit Short To Voltage Cylinder No. 6 Fuel Injector Circuit Short To Voltage Cylinder No. Fuel Injector Circuit Short To Ground Cylinder No. 2 Fuel Injector Circuit Short To Ground Cylinder No. 3 Fuel Injector Circuit Short To Ground P Cylinder No. 4 Fuel Injector Circuit Short To Ground P Cylinder No. 5 Fuel Injector Circuit Short To Ground P Cylinder No. 6 Fuel Injector Circuit Short To Ground P Cylinder No. Fuel Injector Circuit Open Figure 7

49 OBD-II P238 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 7646 Cylinder No. 2 Fuel Injector Circuit Open P P P P P P P P P P P P P P P P P P P P P P P P P Cylinder No. 3 Fuel Injector Circuit Open Cylinder No. 4 Fuel Injector Circuit Open Cylinder No. 5 Fuel Injector Circuit Open Cylinder No. 6 Fuel Injector Circuit Open Fuel Level Too Low Fuel Related Misfire Detected Cylinder No. Knock Control Limit Attained Cylinder No. 2 Knock Control Limit Attained Cylinder No. 3 Knock Control Limit Attained Cylinder No. 4 Knock Control Limit Attained Cylinder No. 5 Knock Control Limit Attained Cylinder No. 6 Knock Control Limit Attained Engine Torque Control Adaptation At Limit Camshaft Position Sensor Circuit Short To Ground Camshaft Position Sensor Circuit Short To Voltage Camshaft/Crankshaft Position Sensor Signals Out Of Sequence Ignition Coil Output Stage No. Circuit Short To Ground Ignition Coil Output Stage No. 2 Circuit Short To Ground Ignition Coil Output Stage No. 3 Circuit Short To Ground ECM Internal Altitude Sensor Error ECM Internal Knock Control Circuit Error Camshaft Position Sensor No. 2 Circuit Short To Ground Camshaft Position Sensor No. 2 Circuit Open Or Short To Voltage Ignition Coil Output Stage No. Circuit Malfunction Ignition Coil Output Stage No. 2 Circuit Malfunction Figure 8

50 OBD-II P395 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 7803 Ignition Coil Output Stage No. 3 Circuit Malfunction P P P P P P P P P P P P P P P P P P P P P P P P P EVAP Canister Purge Regulator Valve Short To Voltage Secondary Air Injection Control Electrical Malfunction Secondary Air Injection Circuit Short To Ground Secondary Air Injection Circuit Short To Voltage Secondary Air Injection System Leak Detected EVAP Canister Purge Regulator Valve Short To Ground EVAP Canister Purge Regulator Valve Circuit Open Secondary Air Injection Circuit Open Secondary Air Injection Pump Relay Circuit Open Secondary Air Injection Pump Relay Short To Voltage Secondary Air Injection Pump Relay Short To Ground Secondary Air Injection Pump Relay Circuit Malfunction Secondary Air Injection Solenoid Valve Circuit Short To Voltage Secondary Air Injection Solenoid Valve Circuit Short To Ground Secondary Air Injection Solenoid Valve Circuit Open EVAP Emission Leak Detection Pump Circuit Short To Voltage EVAP Emission Leak Detection Pump Circuit Short To Ground EVAP Emission Leak Detection Pump Circuit Open EVAP Emission Leak Detection Pump Circuit Malfunction EVAP Emission Leak Detection Pump System Insufficient Vacuum EVAP Emission Leak Detection Pump System Malfunction EVAP Emission Leak Detection Pump System Plugged Fuel Pump Relay Circuit Malfunction Fuel Pump Relay Circuit Short To Ground Fuel Pump Relay Circuit Short To Voltage Figure 9

51 OBD-II P505 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 793 Closed Throttle Position Switch Circuit Open P P P P P P P P P P P P P P P P P P P P P P P P P Closed Throttle Position Switch Circuit Short To Ground Intake Manifold Change-Over Valve Circuit Short To Voltage Intake Manifold Change-Over Valve Circuit Short To Ground Intake Manifold Change-Over Valve Circuit Open Intake Camshaft Control Malfunction Bank Intake Camshaft Control Malfunction Bank 2 Clutch Pedal Switch Signal Implausible Fuel Pump Relay Circuit Open Throttle Actuator Potentiometer Out Of Range Throttle Actuator Potentiometer Signal Too Low Throttle Actuator Potentiometer Signal Too High Throttle Position Control Malfunction Boost Pressure Control Valve Circuit Short To Voltage Boost Pressure Control Valve Circuit Short To Ground Boost Pressure Control Valve Circuit Open Charge Pressure Upper Limit Eceeded Charge Pressure Control Negative Deviation Charge Pressure Control Positive Deviation Throttle Actuator Electrical Malfunction Idle Speed Control Adaptation Malfunction Maimum Engine Speed Eceeded Idle Speed Control Throttle Position Adaptation Malfunction Idle Speed Control Throttle Position Lower Limit Not Attained Idle Speed Control Throttle Position Mechanical Malfunction Cruise Control Switch Signal Implausible Figure 0

52 OBD-II P580 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 7988 Throttle Actuator Potentiometer Signal Malfunction P P P P P P6 809 P P P P P P P P P P P P P P P P P P P Idle Adaptation At Limit ECM Power Supply Voltage Malfunction ECM Voltage Low ECM Internal Malfunction Rough Road Recognition From ABS Control Module MIL Circuit/TCM Short To Ground ECM Coding Incorrect MIL Call-Up Circuit Open Or Short To Voltage MIL Request Signal Active Data Bus Communications Signal Missing From TCM Accelerator Pedal Position Sensor No. Signal Too Low Accelerator Pedal Position Sensor No. Signal Too High Accelerator Pedal Position Sensor No. 2 Signal Too Low Accelerator Pedal Position Sensor No. 2 Signal Too High Accelerator Pedal Position Sensor Out Of Range ECM EEPROM Error Data Bus Communication Signal Malfunction Data Bus Communications Signal Missing From ABS Electronic Power Control Indicator Light Circuit Malfunction Electronic Power Control Indicator Light Circuit Short To Voltage Electronic Power Control Indicator Light Circuit Short To Ground Electronic Power Control Indicator Light Circuit Open ECM Programming Not Finished MIL Circuit Malfunction MIL Circuit Open Figure

53 OBD-II P692 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS GASOLINE ENGINES ECM VAG DEFINITIS 800 MIL Circuit Short To Ground P693 P778 P780 P85 P MIL Circuit Short To Voltage Solenoid EV7 Electrical Malfunction Engine Intervention Readable Data Bus Communications Signal Missing From ABS Control Module Data Bus Message Not Detected Figure 2

54 OBD-II P00 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS DIESEL ENGINES ECM VAG DEFINITIS MAF Sensor Signal Implausible P06 P02 P023 P0300 P030 P0302 P0303 P0304 P032 P0322 P0380 P050 P0560 P0605 P44 P45 P46 P55 P56 P57 P P P P P ECT Sensor Out OF Range Throttle Position Sensor Out Of Range Throttle Position Sensor Circuit Short To Voltage 062 Random Misfire Detected 062 Cylinder No. Misfire Detected 062 Cylinder No. 2 Misfire Detected 062 Cylinder No. 3 Misfire Detected 062 Cylinder No. 4 Misfire Detected 0053 Engine Speed Sensor Circuit Out Of Range 0053 Engine Speed Sensor Circuit No Activity 0050 Glow Plug Monitor Vehicle Speed Sensor Circuit Out Of Range System Voltage Malfunction ECM Failure MAF Sensor Circuit Open Or Short To Ground MAF Sensor Circuit Short To Voltage MAF Sensor Voltage Supply Too High/Low IAT Sensor Circuit Short To Voltage IAT Sensor Circuit Open Or Short To Ground IAT Sensor Voltage Supply Too High/Low IAT Sensor Circuit Short To Ground IAT Sensor Circuit Open Or Short To Voltage Fuel Temperature Sensor Circuit Short To Ground Fuel Temperature Sensor Circuit Open Or Short To Voltage Needle Lift Sensor Circuit Short To Ground Figure 3

55 OBD-II P246 P247 P248 P25 P252 P255 P256 P354 P402 P403 P44 P537 P538 P540 P546 P549 P550 P56 P562 P563 P62 P66 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS DIESEL ENGINES ECM VAG DEFINITIS Needle Lift Sensor Signal Implausible P P P P Needle Lift Sensor Signal Open Or Short To Voltage Injection Start Control Malfunction Cold Start Injector Circuit Short To Voltage Cold Start Injector Circuit Open Or Short To Ground ECT Sensor Circuit Short To Ground ECT Sensor Circuit Short To Voltage Modulating Piston Displacement Sensor Circuit Malfunction EGR Vacuum Regulator Solenoid Valve Circuit Short To Voltage EGR System Control Difference EGR Vacuum Regulator Solenoid Valve Circuit Open Or Short To Ground Fuel Cut-Off Valve Mechanical Malfunction Fuel Cut-Off Valve Circuit Open Or Short To Ground Vehicle Speed Sensor Signal Too High Wastegate By-Pass Regulator Valve Circuit Short To Voltage Wastegate By-Pass Regulator Valve Circuit Open Or Short To Ground Intake Manifold Pressure Control Difference 0268 Quality Adjuster Control Difference Quality Adjuster Upper Limit Attained Quality Adjuster Lower Limit Attained 0044 ECM Incorrect Coding Glow Plug Indicator Light Circuit Short To Voltage Glow Plug Indicator Light Circuit Open Or Short To Ground Glow Plug Relay Circuit Short To Voltage Glow Plug Relay Circuit Open Or Short To Ground Data Bus Message From TCM Implausible Figure 4

56 OBD-II P632 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II ECM DEFINITIS DIESEL ENGINES ECM VAG DEFINITIS Throttle Position Sensor Voltage Supply Too High/Low P693 P694 P85 P MIL Circuit Short To Voltage MIL Circuit Open Or Short To Ground Data Bus Message From ABS Control Module Implausible Data Bus Message Not Detected Figure 5

57 VOLKSWAGEN/AUDI 0M/0N/0P OBD-II TCM DEFINITIS OBD-II P020 TCM VAG DEFINITIS Engine RPM Signal Too High P0700 P0705 P Transmission Control System Malfunction (MIL Request) Multi-Function Switch Signal Implausible (Transmission Range Switch) Transmission Vehicle Speed Sensor Signal Interrupted(Sun Gear Shell Sensor) P0722 P0725 P0730 P Vehicle Speed Sensor Signal Interrupted (Output Shaft Speed Sensor) Throttle Position Sensor Signal Out Of Range Final Drive Ratio Signal Incorrect/Implausible (Gear Ratio Error) Torque Converter Clutch Malfunction (TCC Slip Ecessive) P P P P P P P NA NA NA NA NA P NA NA NA NA 0064 NA Solenoid Valve EV (A) - N88 Electrical Fault Solenoid Valve EV2 (B) - N89 Electrical Fault Solenoid Valve EV3 (C) - N90 Electrical Fault Solenoid Valve EM4 (D) - N9 Electrical Fault Solenoid Valve EV5 (E) - N92 Electrical Fault Pressure Control Solenoid EM6 - N93 Electrical Fault Solenoid Valve EV7 (7) - N94 Electrical Fault Kickdown Switch Electrical Fault Transale Fluid Temperature Sensor Unidentified Malfunction (Circuit Fault) Brake Lamp Switch Circuit Fault B+ Supply Voltage Insufficient Maimum Engine Speed Eceeded (Neutral Condition) Interruption Of Ignition Timing Signal Between ECM And TCM Fuel Consumption Signal Implausible Short Circuit Between Injector Wires Interruption Of Throttle Position Sensor Signal Between ECM And TCM ATF Temperature Signal Too High (Transmission Overheat Protection Program) Transale Range Controller Signal Improper (Mechanical Gear Ratio Error) Figure 6