|
ESP Electrical check
Electrical check; Test steps 13-27
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
13 1)
|
Jumper
1 + 2,
28 + 37
|
Inlet valve -N101 and brake line connection, front left
|
▪ Ignition on.
|
|
|
|
|
|
|
- Move selector lever to "N" on vehicles with automatic gearbox.
Bridge across sockets 5 + 28.
Depress and hold down brake pedal.
|
- Front left wheel can be turned by hand
|
- If the wheel is locked, check whether one of the other wheels can be turned. If so, the hydraulic brake lines have been connected the wrong way round. Check brake pipe connections and unions. Ensure that brakes are working properly.
|
|
|
|
Continued next page.
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
Continued:
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
13 1)
|
Jumper
1 + 2,
28+37 2)
28+36 3)
|
Inlet valve -N101 and brake line connection, front left
|
|
|
- If all wheels are locked, inlet valve is not functioning properly => Fault table, Fault code 00257.
|
|
|
|
|
- Remove bridge connection.
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- Front left wheel locked.
|
|
|
|
|
|
- Release brake pedal.
|
|
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
14 1)
|
Jumper
1 + 2,
28 + 37
|
Inlet valve -N99 and brake line connection, front right
|
▪ Ignition on.
|
|
|
|
|
|
|
- Move selector lever to "N" on vehicles with automatic gearbox.
Bridge across sockets 26 + 28.
Depress and hold down brake pedal.
|
- Front right wheel can be turned by hand.
|
- If the wheel is locked, check whether one of the other wheels can be turned. If so, the hydraulic brake lines have been connected the wrong way round. Check brake pipe connections and unions. Ensure that brakes are working properly.
|
|
|
|
Continued next page.
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
Continued:
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
14 1)
|
Jumper
1 + 2,
28+37 2)
28+36 3)
|
Inlet valve -N99 and brake line connection, front right
|
|
|
- If all wheels are locked, inlet valve is not functioning properly => Fault table, Fault code 00259.
|
|
|
|
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- Remove bridge connection.
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- Front right wheel locked
|
|
|
|
|
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- Release brake pedal.
|
|
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
15 1)
|
Jumper
1 + 2,
28 + 37
|
Inlet valve -N134 and brake line connection, rear left
|
▪ Ignition on.
|
|
|
|
|
|
|
- Move selector lever to "N" on vehicles with automatic gearbox.
Bridge across sockets 53 + 28.
Depress and hold down brake pedal.
|
- Rear left wheel can be turned by hand.
|
- If the wheel is locked, check whether one of the other wheels can be turned. If so, the hydraulic brake lines have been connected the wrong way round. Check brake pipe connections and unions. Ensure that brakes are working properly.
|
|
|
|
Continued next page.
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
Continued:
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
15 1)
|
Jumper
1 + 2,
28+37 2)
28+36 3)
|
Inlet valve -N134 and brake line connection, rear left
|
|
|
- If all wheels are locked, inlet valve is not functioning properly => Fault table, Fault code 00274.
|
|
|
|
|
- Remove bridge connection.
|
- Rear left wheel locked
|
|
|
|
|
|
- Release brake pedal.
|
|
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
16 1)
|
Jumper
1 + 2,
28 + 37
|
Inlet valve -N133 and brake line connection, rear right
|
▪ Ignition on.
|
|
|
|
|
|
|
- Move selector lever to "N" on vehicles with automatic gearbox.
Bridge across sockets 6 + 28.
Depress and hold down brake pedal.
|
- Rear right wheel can be turned by hand.
|
- If the wheel is locked, check whether one of the other wheels can be turned. If so, the hydraulic brake lines have been connected the wrong way round. Check brake pipe connections and unions. Ensure that brakes are working properly.
|
|
|
|
Continued next page.
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
Continued:
|
Functional check + test for correct connections
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
16 1)
|
Jumper
1 + 2,
28+37 2)
28+36 3)
|
Inlet valve -N133 and brake line connection, rear right
|
|
|
- If all wheels are locked, inlet valve is not functioning properly => Fault table, Fault code 00273.
|
|
|
|
|
- Remove bridge connection.
|
- Rear right wheel locked
|
|
|
|
|
|
- Release brake pedal.
|
|
|
The output connections on control unit -J104 are wired differently for the various different versions.
1) Two mechanics are required to perform this test.
2) Vehicles with control unit 4B0 907 389
3)Vehicles with control unit 8D0 907 389/A/D/E
|
Functional check: ABS warning lamp-K47
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
17
|
-
|
Function of ABS warning lamp -K47
|
▪ Fault memory was interrogated and there is no fault present in the fault memory of the control unit -J104.
▪ Ignition switched off
▪ Multi-pin connector connected to control unit -J104 and engaged.
|
|
|
|
|
|
Continued next page.
|
Continued:
|
Functional check: ABS warning lamp-K47
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
17
|
-
|
Function of ABS warning lamp -K47
|
- Switch on ignition.
|
Warning lamp -K47 is lit up for 2 seconds and then goes out again.
|
- If ABS warning lamp does not light check electrical system voltage and wiring from contact 32 of control unit -J104 to dash panel insert for short to earth.
|
|
|
|
Continued next page.
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Continued:
|
Functional check: Red brake fault symbol
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
18
|
-
|
Function of red symbol "Fault brake system"
|
▪ Brake fluid level OK
|
|
|
|
|
|
Continued next page.
|
Continued:
|
Functional check: Red brake fault symbol
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
18
|
-
|
Function of red symbol "Fault brake system"
|
- Connect V.A.G 1551, select address word 03
On vehicles with automatic gearbox and dash panel insert with FIS, press brake pedal and engage a gear.
|
ABS/EDL warning lamp and red brake fault symbol should light up. TCS/ESP warning lamp will also light up if it is working properly.
|
- Fault in dash panel insert
|
|
|
|---|
|
Functional check: TCS/ESP warning lamp -K86.
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
19
|
-
|
Function of TCS/ESP warning lamp -K86
|
▪ Fault memory was interrogated and there is no fault present in the fault memory of the control unit -J104.
▪ Ignition switched off
▪ Multi-pin connector connected to control unit -J104 and engaged.
|
|
|
|
|
|
Continued next page.
|
Continued:
|
Functional check: TCS/ESP warning lamp -K86.
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
19
Continued:
|
-
|
Function of TCS/ESP warning lamp -K86
|
- Switch on ignition.
|
Warning lamp -K86 should light up for 2 seconds and then extinguish.
|
- If the TCS/ESP warning lamp does not light up, check voltage of electrical system and test wiring from contact 31 of control unit -J104 to dash panel insert for open circuit and short to positive.
If TCS/ESP warning lamp lights continuously check wiring from contact 31 of control unit -J104 to dash panel insert for short to earth.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
|
|
Continued next page.
|
Continued:
|
|
|---|
|
Functional check: TCS/ESP switch, select measuring range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
20
|
-
|
Function of TCS/ESP switch
|
▪ Ignition switched off
▪ Function of TCS/ESP warning lamp -K86 checked in test step 19.
▪ Multi-pin connector connected to control unit -J104 and engaged.
|
|
|
|
|
|
Continued next page.
|
Continued:
|
Functional check: TCS/ESP switch, select measuring range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
20
|
-
|
Function of TCS/ESP switch
|
- Switch on ignition.
|
|
|
|
|
|
|
- Press TCS/ESP switch.
|
Warning lamp for TCS/ESP -K86 lights.
|
- Switch off the ignition.
Release multiple connector from control unit -J104 and detach.
|
|
|
|
|
- Operate TCS/ESP switch again
|
TCS/ESP Warning lamp -K86 goes out.
|
- Connect test box V.A.G 1598/20.
|
|
|
|
Continued next page.
|
Continued:
|
Functional check: TCS/ESP switch, select measuring range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
20
|
28 + 44
|
Function of TCS/ESP switch
|
▪ Ignition switched on
|
|
|
|
|
|
|
- TCS/ESP switch not pressed
|
0.0 - 1.0 V
|
- Check wiring from contact 28 to earth.
Check wiring from contact 44 to TCS/ESP switch, contact 6.
Check voltage supply from contact 5 of TCS/ESP switch to terminal 15.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
|
|
Continued next page.
|
Continued:
|
|
|---|
|
Functional check: TCS/ESP switch, select measuring range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
20
|
28 + 44
|
Function of TCS/ESP switch
|
- TCS/ESP switch is pressed.
|
10.0 - 14.5 V
|
- Check wiring from contact 28 to earth.
Check wiring from contact 44 to TCS/ESP switch, contact 6.
Check voltage supply from contact 5 of TCS/ESP switch to terminal 15.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
If no fault could be detected during the test steps already carried out the TCS/ESP switch must be replaced.
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
21
|
1 + 28
1 + 29
|
Voltage supply of control unit through terminal 15
|
▪ Ignition switched on
|
10.5 - 14.5 V
|
- Check wiring from contacts 28 and 29 to earth.
Check wiring from terminal 1 via fuse (10A) to terminal 15.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
22
|
-
|
Voltage supply of solenoid valves via solenoid valve relay -J106.
|
- Remove solenoid valve relay -J106
|
|
|
|
|
|
|
- Test voltage supply of solenoid valve relay -J106, contact 30, for open circuit and short to positive or earth.
|
10.5 - 14.5 V
|
- Check relevant fuse (25A) and repair damaged wiring
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
22
|
-
|
Voltage supply of solenoid valves via solenoid valve relay -J106.
|
- Check wiring from solenoid valve relay -J106, contact 87 to hydraulic unit -N55, contact 10 for open circuit and short to positive/earth.
|
|
- Repair damaged wiring
If voltage supply wiring is OK, renew relay.
If the original fault "solenoid valve relay -J106" has still not been rectified, renew hydraulic unit.
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
23
|
-
|
Supply voltage to return pump relay -J105 by terminal 30
|
- Remove return pump relay -J105.
|
|
|
|
|
|
|
- Check voltage supply of return pump relay -J105, at contact 30, for open circuit and short to positive or earth.
|
10.5 - 14.5 V
|
- Check relevant fuse (60A) and repair damaged wiring
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
24
|
-
|
- Earth and voltage supply for return pump -V39
|
- Remove return pump relay -J105.
|
|
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
24
|
-
|
- Earth and voltage supply for return pump -V39
|
- Check wiring from solenoid valve relay -J105, contact 87 to control unit -J104, contact 20 and hydraulic unit -N55, contact 24 for open circuit or short to positive/earth.
|
|
- Repair damaged wiring
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
24
|
-
|
- Earth and voltage supply for return pump -V39
|
- Check earth connection of return pump at hydraulic unit -N55, contact 13.
|
|
- Rectify open circuit or short to positive in earth connection.
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
24
|
Jumper
7 + 28,
1 + 2
|
- Function of return pump relay -J105.
|
▪ Return pump relay -J105 is installed.
|
|
|
|
|
|
|
- Measure voltage between sockets 20 and 29 on V.A.G 1598/20.
|
- Voltage across sockets 20 +29 should be 10.5 - 14.5 V.
|
|
|
|
|
|
- Switch on ignition for not longer than 10 seconds; switch off ignition.
|
- Return pump -V39 should run.
|
- Replace relay if no voltage is measured between sockets 20 and 29.
If voltage is measured between sockets 20 and 29 return pump is defective and ABS hydraulic unit -N55 is to be replaced.
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
25
|
51 + 28
|
Control unit -J104 is supplied with power at contact 51 via terminal 30. This voltage supply enables control unit -J104 to provide power for EPS hydraulic pump -V156.
|
- Check wiring from control unit -J104 contact 51 to terminal 30 for open circuit and short to earth.
|
10.5 - 14.5 V
|
- Check relevant fuse (25A) and repair damaged wiring
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
26
|
28 + 48
|
Function of brake light switch -F
|
▪ Ignition switched off
|
|
- Check wiring from contact 28 to earth.
|
|
|
|
|
▪ Brake pedal not operated
Brake pedal operated
|
0.0 - 1.0 V
10.0 - 14.5 V
|
- Check wiring from terminal 48 via fuse (10A) to terminal 30.
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
26
|
28 + 42
|
Function of brake light switch-F
(brake test switch)
|
▪ Brake pedal not operated
Brake pedal operated
|
10.0 - 14.5 V
0.0 - 1.0 V
|
- Check wiring from terminal 42 via fuse (10A) to terminal 15.
|
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
27
|
1 + 76
|
Function of handbrake warning switch -F9
|
▪ Ignition switched on
|
|
- Check wiring from terminal 1 via fuse (10A) to terminal 15.
|
|
|
|
|
▪ Handbrake not applied
Handbrake applied
|
0.0 - 1.0 V
10.0 - 14.5 V
|
- Check wiring from contact 76 to handbrake warning switch -F9 for open circuit/short to positive.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
|
|
|
|
Continued next page.
|
Continued:
|
Select voltage test range on V.A.G 1526: 20 V =
|
|
Test step
|
V.A.G 1598/20 sockets
|
Testing of
|
▪ Test conditions
- Additional operations
|
Specified value
|
Action in the event of deviation from specified value
|
|
27
|
1 + 76
|
Function of handbrake warning switch -F9
|
▪ Handbrake not applied
Handbrake applied
|
0.0 - 1.0 V
10.0 - 14.5 V
|
- Check earth connection of handbrake warning switch -F9.
=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder
If no fault could be detected during the test steps already carried out the handbrake warning switch -F9 must be replaced.
|
|
