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AC electrical check
Test in vehicles with an operating and display unit with two displays
List of envisaged electrical checks (at operating and display unit -E87)
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Test step
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Component tested
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Page
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1
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- Power supply, earth connection and illumination of operating and display unit -E87.
Signal for ignition off time
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01-134
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2
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- Temperature sensors/senders (-G17, -G89, -G191, -G151, -G192).
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01-140
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3
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- Fresh air blower with corresponding control unit (-V2, -J126).
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01-143
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4
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- Positioning motors for air conditioner and corresponding potentiometers
(-V68/-G92, -V70/-G112, -V71/-G113, -V85/-G114).
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01-145
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5
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- Air conditioner pressure switch -F129 /
Signal from control unit for radiator fan -J293.
Temperature sensor blower -V42.
"Air conditioner compressor cut-in" output.
Signal "Engine temperature too high".
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01-148
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6
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- Actuation of air conditioner magnetic clutch -N25.
Actuation of radiator fan -V7
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01-157
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Test step 1
Power supply, earth connection and illumination of operating and display unit -E87.
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/12 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.1
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9
and
15
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Terminal 15 and earth connection on -E87
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▪ Ignition on
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- Approx. battery voltage
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- Use current flow diagram to repair power supply and/or earth connection
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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1.2
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7 and
earth
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Terminal 58 on -E87
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▪ Ignition on.
▪ Switch side lights on
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- Approx. battery voltage
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- Use current flow diagram to repair power supply
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Notes:
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◆ Test steps 1.3 to 1.5 must be implemented only for model year 1997 vehicles (operating and display unit with part no. 8L0 820 043 up to and including index "C").
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◆ Earth applied e.g. to connector D contact 15.
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.3
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7 and
earth
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Terminal 58 on -E87
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▪ Ignition on
▪ Side lights off
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- less than 2 V
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- Use the current flow diagram to rectify short to positive
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1.4
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45 and
earth
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Terminal 58d on -E87
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▪ Ignition on
▪ Side lights on
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- 0 to 12 V (regardless of the illumination control setting)
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.5
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45 and
earth
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Terminal 58d on -E87
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▪ Ignition on
▪ Side lights off
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- 0 to 12 V (regardless of the illumination control setting)
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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Note:
Earth applied e.g. to connector D contact 15.
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Voltage tester V.A.G 1527,
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.6
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33
and earth
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Signal for ignition off time
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▪ Ignition on
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- the LED illuminates in voltage tester
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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1.7
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33
and earth
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Signal for ignition off time
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▪ Ignition on
Start engine
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- the LED illuminates in voltage tester
when the engine is started, the LED in the voltage tester flickers briefly (time signal) and remains illuminated
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- Use current flow diagram to locate and eliminate open circuit or short circuit
Check dash panel insert.
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Note:
Earth applied e.g. to connector D contact 15.
Note:
The test steps 1.8 to 1.11 must not be carried out in vehicles of model year 1997 (operating and display unit with part number 8 L0 820 043 and the indices "B" or "C").
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.8
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7 and
earth
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Terminal 58s on -E87
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▪ Ignition on.
▪ Side lights switched on.
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- 0 to 12 V
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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1.9
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7 and
earth
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Terminal 58s on -E87
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▪ Ignition on.
▪ Side lights off
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- approx. 0 V
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- Use the current flow diagram to locate and rectify short to positive
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Notes:
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◆ Earth applied e.g. to connector D contact 15.
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◆ The voltage at terminal 58s is governed by the setting of the illumination control.
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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1.10
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45 and
earth
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Terminal 58d on -E87
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▪ Ignition on
▪ Side lights on
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- 0 to 12 V
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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1.11
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45 and
earth
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Terminal 58d on -E87
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▪ Ignition on
▪ Side lights off
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- 0 to 12 V
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- Use current flow diagram to locate and eliminate open circuit or short circuit
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Notes:
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◆ Earth applied e.g. to connector D contact 15.
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◆ The voltage at terminal 58d is generated as a square-wave signal by the dash panel insert. The brightness of -E87 displays is determined by the actuation time. The measuring instrument displays the average value.
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◆ The actuation time at terminal 58d is governed by the illumination control setting and the brightness level determined by the photosensor in the dash panel insert.
Test step 2
Temperature sensor/sender
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (20 kω)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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2.1
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48
and
49
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Ambient temperature sensor -G17
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- Measure temperature at the sensor fitting location.
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- Governed by the temperature at the sensor/pickup fitting location
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- Use current flow diagram to locate and eliminate short circuit, open circuit or contact resistance.
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2.2
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50
and
49
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Dash panel temperature sensor -G56
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- Measure temperature at the sensor fitting location.
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=> Table, Page 01-142.
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- Replace temperature sensor/sender.
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2.3
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47
and
49
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Temperature sensor for fresh air intake duct -G89
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- Measure temperature at the sensor fitting location.
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2.4
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25
and
49
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Footwell vent temperature sender -G192
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- Measure temperature at sender fitting location.
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (20 kω)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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2.5
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26
and
49
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Centre vent temperature sender -G191
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- Measure temperature at the sensor fitting location.
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- Governed by the temperature at the sensor fitting location => Table, Page 01-142.
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- Use current flow diagram to locate and eliminate short circuit, open circuit or contact resistance.
Replace sensor.
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Notes:
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◆ Centre vent temperature sender -G191 is only installed in vehicles with map-controlled cooling.
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◆ Correct assignment and coding of the operating and display unit -E87 must be ensured in vehicles with map-controlled cooling.
Ambient temperature-dependent resistance of temperature sensors/senders in kω(kilo-ohms)
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At sensor/sender installation location, temperature measured in °C
(degrees Celsius)
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Temperature sensor
-G56
Sender
-G192
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Temperature sensor
-G17
-G89
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Sender
-G191
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-30
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(52.7)
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18.1
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-
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-20
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(28.6)
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9.95
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-
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-10
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16.2
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5.59
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(47)
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0
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9.40
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3.28
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(29)
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5
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7.27
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2.54
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(23)
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10
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5.66
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1.99
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18.5
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15
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4.45
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1.57
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15
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20
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3.50
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1.25
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12.2
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25
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2.79
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1.00
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10.0
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30
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2.23
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0.80
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8.3
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35
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1.80
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0.65
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6.8
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40
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1.45
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0.53
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5.7
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50
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0.97
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0.36
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4.1
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60
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0.67
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0.25
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2.9
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70
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0.47
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-
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2.2
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Test step 3
Fresh air blower -V2 and relevant control unit -J216
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Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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3.1
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16
and
earth
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Control unit -J126
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▪ Ignition on
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- Voltage less than 5 V
Fresh air blower not running
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- Use current flow diagram to locate and eliminate short to positive in the wiring between -J126 and -E87.
Replace control unit -J126.
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3.2
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14
and
earth
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Power supply for fresh air blower -V2
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▪ Ignition on
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- approx. battery voltage
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- Use current flow diagram to repair power supply.
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3.3
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11
and
earth
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Power supply for control unit -J126 (via fresh air blower -V2)
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▪ Ignition on
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- approx. battery voltage
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- Use current flow diagram to repair power supply.
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Note:
Earth applied e.g. to connector D contact 15.
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Voltage tester V.A.G 1527,
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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3.4
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14
and
16
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Control unit -J126
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▪ Ignition on.
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- LED in voltage tester lights up
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- Use current flow diagram to locate and eliminate open circuit in the wiring between -J126 and -E87.
Find open circuit in earth wiring to -J126 and eliminate.
Check freedom of movement of fresh air blower -V2.
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- Fresh air blower is running
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- Replace control unit -J126.
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Test step 4
Positioning motors for air conditioner and associated potentiometers
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (20 kω)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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4.1
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52
and
28 /
29 /
37 /
30
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Potentiometer (in the positioning motor)
-G 92 (-V 68)
-G112 (-V70)
-G113 (-V71)
-G114 (-V85)
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- Greater than 0.1 kωand less than 5.7kω ((depending on the setting of the positioning motor)
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- Use current flow diagram to locate and eliminate open circuit, contact resistance or short circuit
Replace positioning motor
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4.2
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8
and
28 /
29 /
37 /
30
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Potentiometer (in the positioning motor)
-G 92 (-V 68)
-G112 (-V70)
-G113 (-V71)
-G114 (-V85)
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- Greater than 0.1 kωand less than 5.7kω ((depending on the setting of the positioning motor)
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- Use current flow diagram to locate and eliminate open circuit, contact resistance or short circuit
Replace positioning motor
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Notes:
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◆ The resistance of potentiometers in the positioning motors (specified value: 3.6 kωto 5.7 kω between contact 1 and 3) can only be measured directly on the positioning motor (parallel connection).
-
◆ The resistance of the potentiometers in the positioning motors (between contacts 1 and 2, as well as contacts 3 and 2) is governed by the setting of the positioning motor, it must only be measured with the positioning motorfitted. The maximum specified value will not be obtained in test steps 4.1 and 4.2. (To obtain the maximum specified value, all connectors on the other positioning motor would have to be detached during the measurement; the motors are connected in parallel).
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◆ If -E87 detects the fault "potentiometer short to earth or open circuit/short to positive", check all the potentiometers (in the 4 positioning motors) and the corresponding wiring.
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◆ On vehicles with right-hand drive, connections 1 and 3 as well as 4 and 6 on the positioning motor are reversed (check part number and current flow diagram).
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (200 ω)
- Adapter cable V.A.G 1598/12 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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4.3
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2
and
10
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Temperature flap positioning motor -V68
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- 20 ωto 100ω.
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- Use current flow diagram to locate and eliminate open circuit, contact resistance or short circuit
Replace positioning motor
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (200 ω)
- Adapter cable V.A.G 1598/12 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
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Specified value
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Remedies if specified value not attained
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4.4
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4
and
12
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Central flap positioning motor -V70
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- 20 ωto 100ω.
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- Use current flow diagram to locate and eliminate open circuit, contact resistance or short circuit
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4.5
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5
and
13
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Air flow flap positioning motor -V71
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- 20 ωto 100ω.
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- Replace positioning motor
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4.6
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3
and
11
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Footwell/defroster flap positioning motor -V85
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- 20 ωto 100ω.
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Test step 5
Pressure switch -F129 / signal from radiator fan control unit -J293, "AC compressor cut-in" output, "engine temperature too high" signal and temperature sensor blower -V42
Notes:
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◆ High-pressure sensor -G65 will gradually replace air conditioner pressure switch -F129 (as of model year 1999, initially vehicles with 1.6 l engines).
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◆ Test step 5.1 must be implemented only for vehicles with pressure switch -F129.
-
◆ Test steps 5.2 to 5.5 are identical for vehicles with pressure switch -F129 and high-pressure sensor -G65.
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◆ Test step 5.6 must be implemented only for vehicles with high-pressure sensor -G65.
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Select measuring range on hand-held multimeter V.A.G 1526:
Resistance measurement (200 ω)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
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▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
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5.1
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2
and
42
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Air conditioner pressure switch -F129 (switch between the contacts 1 and 2)
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▪ Ignition off.
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- Less than 20 ω
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- Use current flow diagram to locate and eliminate open circuit or contact resistance.
Check pressure switch -F129 (=>Seite 87-18).
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Notes:
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◆ Test step 5.1 must be implemented only for vehicles with pressure switch -F129.
-
◆ If code 1 "pressure switch -F129 open" is displayed in measured value block 1 as a compressor shutoff criterion:
- Also use current flow diagram to check the wiring to -F129 for a loose contact.
- Check the actuation of the radiator fan -V7 speed 1 (=>Final control diagnosis, Page 01-51).
- Check AC pressure switch -F129 (switch between contacts 3 and 4, actuation of radiator fan
-V7 speed 2) (=>Page 87-18).
If no fault can be determined, the vehicleshould be sent to an VW and Audi air conditioner service centre.
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Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (20 A =)
- Adapter cable V.A.G 1598/11 connected
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Test step
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V.A.G 1598 socket
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Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
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5.2
|
44
and
earth
|
Temperature sensor blower -V42.
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▪ Ignition on.
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- less than 1 A.
Blower running.
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- Use current flow diagram to locate and eliminate open circuit or short to positive or earth in the wiring between -V42 and -E87.
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Notes:
-
◆ Test steps 5.2 to 5.5 are identical for vehicles with pressure switch -F129 and high-pressure sensor -G65.
-
◆ Earth applied e.g. to connector D contact 15.
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Voltage tester V.A.G 1527,
Operating and display unit connected to the test box (adapter cable V.A.G 1598/11 and /12)
- Adapter cable V.A.G 1598/11 connected
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Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
5.3
|
Earth
and
51
|
Signal "Engine temperature too high"
|
▪ Engine running
|
▪ LED in the voltage tester flickers briefly.
|
- Use the current flow diagram to locate and rectify short to earth.
Rectify the air conditioner compressor shutoff condition in the dash panel insert.
|
Notes:
-
◆ If the LED does not illuminate and there is not short circuit to earth to socket 51, this test step must be truncated for model year 1997 and 1998 vehicles - the connection has not been installed in these vehicles.
-
◆ Earth applied e.g. to connector D contact 15.
-
◆ Brief flickering of the LED in the voltage tester indicates that the dash panel insert is transmitting a temperature signal.
-
◆ In vehicles from model year 2000, the assignment of the ignition key will be transmitted to the -E87 by the dash panel insert together with the refrigerant temperature and the signal "Engine temperature too high" when the ignition is switched on (data telegram).The assignment of the key can only be processed by operating and display units with the part number 8D0 820 043 as from index "H". If the refrigerant temperature is too high, no information may be transmitted.
-
◆ The assignment of the ignition key can only be recognised and therefore transmitted by the dash panel insert on vehicles fitted with an immobiliser.
-
◆ When the ignition is switched on, the -E87 starts with the setting which was valid the last time the ignition was switched off with this key (temperature, air distribution, fresh air blower speed).
-
◆ The signal from the dash panel insert (data telegram) cannot be checked with workshop tools.
=> Electrical System; Repair group 90; Repair dash panel insert
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|---|
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Voltage tester V.A.G 1527,
Operating and display unit connected to the test box (adapter cable V.A.G 1598/11 and /12)
- Adapter cable V.A.G 1598/11 connected
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
5.4
|
14
and
12
|
"Air conditioner compressor cut-in" output
|
▪ Engine running
▪ Compressor switched off (frost symbol in the display zone of -E87 is not illuminated).
Switch on compressor.
|
- LED in voltage tester lights up.
LED in voltage tester lights up a little less brightly.
|
- Use current flow diagram to locate and eliminate open circuit or short circuit.
Rectify AC compressor shutoff condition in the engine control (emergency operation).
Rectify AC shutoff condition in the automatic gearbox control unit -J217.
Use the current flow diagram to locate and rectify short to earth.
|
|
|
|---|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (200 mA =)
Operating and display unit connected to the test box (adapter cable V.A.G 1598/11 and /12)
- Adapter cable V.A,G 1598/11 connected.
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
5.5
|
Earth
and
12
|
"Air conditioner compressor cut-in" output
|
▪ Engine running
▪ Compressor switched off.
Switch on compressor.
|
- Less than 5 mA
Less than 50 mA
Compressor is not switched on.
|
- Use current flow diagram to locate and eliminate short circuit.
Check actuation of control unit -J293 (=>Page 01-187).
Renew operating and display unit -E87.
|
|
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|---|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Voltage measurement (20V =)
- Adapter cable V.A.G 1598/11 connected
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
5.6
|
2
and
earth
|
Signal from radiator fan control unit -J293 (in vehicles with high-pressure sensor -G65)
|
▪ Ignition on.
|
- approx. battery voltage
|
- Use current flow diagram to locate and eliminate open circuit or contact resistance.
Check high-pressure sensor (=>Page 01-225).
|
Notes:
-
◆ Test step 5.6 must be implemented only for vehicles with high-pressure sensor -G65.
-
◆ Earth applied e.g. to connector D contact 15.
-
◆ Depending on high-pressure sensor -G65 signal, radiator fan control unit -J293:
- indicates to operating and display unit -E87 that the refrigerant circuit pressure is OK and the compressor
can be switched on (via magnetic clutch -N25).
- switches radiator fan to 2nd speed if pressure increases.
-
◆ High-pressure sensor -G65 will gradually replace air conditioner pressure switch -F129 (as of model year 1999, initially vehicles with 1.6 l engines).
-
◆ If code 1 "pressure switch -F129 open" is displayed in measured value block 1 as a compressor shutoff criterion:
- Use current flow diagram to check the wiring to -G65 for a loose contact.
- Use current flow diagram to check wiring between control unit -J293 and -E87 for loose contact.
- Check the actuation of the radiator fan -V7 speed 1 (=>Final control diagnosis, Page 01-51).
- Check signal from high-pressure sensor -G65 =>Page 01-225.
Test step 6
Radiator fan actuation -V7, magnetic clutch actuation -N25
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|
|---|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (20 A =)
- Adapter cable V.A.G 1598/11 connected
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
6.1
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14
and
42
|
Actuation of radiator fan -V7
|
▪ Engine running
|
- Less than 1 A
Radiator fan -V7 running at speed 1 (observe relevant notes)
|
- Use current flow diagram to locate and eliminate open circuit or short to positive or earth in the wiring between -J293 and -E87.
Check actuation of control unit -J293 (=>Page 01-187).
Control unit -J293 defective - replace.
|
|
|
|
|
|
|
|
|
|
(cont.)
▼
|
|
|
|---|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (20 A =)
- Adapter cable V.A.G 1598/11 connected
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
6.1
(cont.)
|
|
Actuation of air conditioner magnetic clutch -N25
|
▪ Engine running
|
- Compressor is driven.
|
- Open pressure switch -F129 (checking =>Test step 5).
Use current flow diagram to locate and eliminate open circuit or short to positive or earth in the wiring between -E87 and -J293.
Check actuation of control unit -J293 (=>Page 01-187).
Refrigerant temperature switch -F14 defective (open) or refrigerant too hot - check.
Control unit -J293 defective - replace.
|
Notes:
-
◆ Radiator fan -V7 is automatically switched on together with the magnetic clutch in vehicles with pressure switch for air conditioner -F129.
-
◆ Control unit -J293, installed in vehicles with high-pressure sensor -G65, is available in 2 designs.
- In design "1" the radiator fan is automatically switched on in conjunction with the compressor (the first fan speed
is activated regardless of the pressure in the refrigerant circuit).
- In design "2" the compressor is switched on without actuation of the radiator fan; the first
fan speed is only activated once the pressure in the refrigerant circuit exceeds 12 bar.
-
◆ Refrigerant temperature switch -F14 must be implemented only for vehicles with pressure switch -F129.
Note:
Test step 6.2 must be implemented only for vehicles with pressure switch -F129.
|
|
|---|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (20 A =)
- Adapter cable V.A.G 1598/11 connected
|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
6.2
|
10
and
14
|
Actuation of radiator fan -V7 (speed 2)
|
▪ Engine running
|
- less than 1 A.
Fan running at speed 2.
|
- Use current flow diagram to locate and eliminate open circuit or short to positive or earth in the wiring between -E87 and control unit -J293.
Use current flow diagram to locate and eliminate open circuit in the wiring between control unit -J293 and fans -V7.
|
|
|
|
|
|
|
|
|
|
(cont.)
▼
|
|
|
|---|
|
Test step
|
V.A.G 1598 socket
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Remedies if specified value not attained
|
|
Select measuring range on hand-held multimeter V.A.G 1526:
Current measurement (20 A =)
- Adapter cable V.A.G 1598/11 connected
|
|
6.2
(cont.)
|
10
and
14
|
Actuation of radiator fan -V7 (speed 2)
|
▪ Engine running
|
- less than 1 A.
Fan running at speed 2.
|
- Check actuation of control unit -J293 (=>Page 01-187).
Check radiator fan -V7.
=> Current Flow Diagrams, Electrical Fault-Finding and Fitting Locations
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|
