volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Final control diagnosis > < Interrogating and erasing fault memory
Motronic injection and ignition system (6-Cyl. engine)
Fault memory
Fault table

Notes:

  • ◆ The fault tables are listed according to the 5 digit fault code on the left.
  • ◆ Explanation of the fault types (e.g. "open circuit/short circuit to earth"):

=> Fault reader operating instructions

  • ◆ If components are indicated as faulty:
    First check the wiring and connectors to these components as well as the system earth connections according to current flow diagram. This is particularly relevant if faults are output as "occurring sporadically" (SP).

V.A.G 1551 print-out

Possible fault cause

Fault elimination

No fault recognised!

If a fault is present:
Fault not recognised by self diagnosis

Continue fault finding using fault table: =>"Engine fault finding" binder.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00281

Road speed sender
G68

Implausible signal

No signal from electronic speedometer (G21)1) or speedometer sender (G22)

- Check speed signal

Wiring open circuit

- Locate and eliminate wiring open circuit using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

No signal

Speedometer does not indicate vehicle speed:

Speedometer sender (G22) defective

- Replace G22

- Continue fault finding according to fault finding programme for MFI:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

1)     Checking the road speed signal is carried out when driving the vehicle at an engine speed between 2500 and 3000 rpm.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00282

Throttle valve positioner -V601)

Short to earth

Wire has short to earth

- Check V60 ,
checking throttle valve control part

V60 defective/sticking in closed direction

Short to positive

Wire has short to positive

V60 defective/sticking in open direction

Open circuit

Wiring open circuit

1)     The throttle valve positioner V60 is a component of the throttle valve control part J338.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00513

Engine speed sender -G28

No signal

Wiring open circuit

- Check G28 => Page 24-70

G28 defective

- Replace G28 => Page 24-10 , item 10

Implausible signal1)

Gap sender/sender wheel too large

- Check G28 is seated securely/metal particles => Page 24-10 , item 10

Metal particles on G28 or holder loose

Sender wheel defective, loose

- Check sender wheel is seated securely:
=> Repair group 13; Removing and installing crankshaft

1)     In isolated cases, fault may be stored as a result of engine being abruptly stalled (sporadic fault).

Note on fault code 00513:

If due to a defect the engine does not run: Before interrogating the fault memory operate the starter for at least 5 seconds and then do not switch the ignition off . Because there is no signal from the engine speed sender when the engine is not running, the self diagnosis could mistakenly recognise an engine speed sender -G28 fault. If the fault remains stored in the fault memory, check the sender as described.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00515

Hall sender -G40

Hall sender (G40) rotor twisted1), camshaft timing out

- Check G401) => Page 28-8

Open/short circuit to positive

- Check valve timing:
=> Repair group 13; dismantling and assembling engine; setting timing

Wiring open circuit or wiring/G40 has short circuit to positive1)2)

Short circuit to earth

Short circuit to earth in wiring or G40

1)     Only for Motronic with distributor

2)     Only for Motronic with electronic high-voltage distributor

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00516

Idling switch F601)

F60 defective, always closed

- Check F60 ,
checking throttle valve control part

Short to earth

Wiring has short to earth

Open circuit/short circuit to positive

F60 defective, always open

Wiring open circuit

Accelerator cable incorrectly adjusted

- Adjust accelerator cable
=> Repair Group 20; Removing and installing parts of the fuel supply system; Servicing accelerator cable

1)     The idling switch F60 is a component of the throttle valve control part J338.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00518

Throttle valve potentiometer
-G691)

Open circuit/short to positive

Wiring open circuit/wiring or G69 has short to positive

- Check G69 ,
Checking throttle valve control part

Open circuit/short to earth

G69 defective/wire has short to earth

- On vehicles ▸07.95 without throttle valve control part, check G69 => Page 24-54

1)     The throttle valve potentiometer G69 for vehicles approx. 08.95 ▸is a part of the throttle valve control part J338.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00522

Coolant temperature sender
-G62

Short to earth

G62 defective

- Replace G62 => Page 24-9 , item 5

Wire has short to earth

- Check G62

Open circuit/short to positive

G62 defective, or incorrect working range caused by corrosion on connector

Wiring open circuit/wire has short to positive

Implausible signal

G62 defective

- Replace G62 => Page 24-9 , item 5

Thermostat defective (permanently open)

- Check thermostat
=> Repair group 19; Removing and installing parts of the cooling system; Removing and installing thermostat housing;

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00524

Knock sensor 1 -G61

Open circuit/short to earth

G61 defective

- Replace G61 => Page 28-5 , item 12

Wiring open circuit/short to earth in the sensor wire

- Check G61
=> Page 28-16 , checking knock sensors

No knock recognition from Motronic control unit (J220)

- If necessary replace J220
=> Page 24-8 , item 2

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00525

Lambda probe -G39

No signal

G39 defective

- Replace G39 => Page 24-9 , item 4

Lambda probe heating defective

- Check Lambda probe heating

Wiring open circuit

- Check Lambda probe and Lambda control

Short circuit to positive

Short circuit to positive in wiring or G39

Short circuit to earth

Short circuit to earth in wiring or G39

Fuel tank empty

- Fill tank / erase fault memory
=> Page 01-13 , interrogating and erasing fault memory

Implausible signal

G39 defective

- Replace G39 => Page 24-9 , item 4

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00527

Intake manifold temperature sender
-G72

Short to earth

G72 defective

Wire has short to earth

- Check G72 => Page 24-65

Open circuit/short to positive

G72 defective, or incorrect working range caused by corrosion on connector

- Replace G72 => Page 24-16 , item 16

Wiring open circuit/wire has short to positive

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00530

Throttle valve positioner/potentiometer -G881)

Short to earth

Wire has short to earth

- Check G88 ,
Checking throttle valve control part

Wiring open circuit in earth wire

G88 defective

Short to positive

Wiring open circuit in earth wire

Wire has short to positive

G88 defective

Open circuit

Wiring open circuit

Implausible signal

Connector incorrectly wired

Control difference

G88 defective

Control limit exceeded

1)     The throttle valve positioner/potentiometer G88 is a component of the throttle valve control part J338.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00532

Supply voltage1)

Signal too large

Battery voltage above 16.0 V

- Check alternator:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Signal too small

Battery voltage below 10.0 V

- Check battery:
=> Electrical system; Repair group 27;
=> Checking and charging battery

- Check engine control unit voltage supply => Page 24-112

1)     Fault detection: Motronic control unit (J220) checks voltage after engine has been running for 3 minutes

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00533

Idling speed control

Adaption limit exceeded

Throttle valve positioner/potentiometer G88 defective

- Check G88 ,
checking throttle valve control part

Adaption limit not reached

Unmetered air between air mass meter (G70) and engine

- Check intake air system for leaks
(unmetered air) => Page 24-75

00535

First knock control

Motronic control unit (J220) knock control defective

- Replace J220 if necessary
=> Page 24-8 , item 2

Implausible signal

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00537

Lambda control

Exhaust system leaking between cylinder head and catalyst

- Check exhaust system:
=> Repair group 26; removing and installing parts of exhaust system

Control limit exceeded

Misfiring

- Check ignition part components
=> Page 28-20 1)

Intake system leaking

- Check intake system for leaks (unmetered air)

Injector(s) (N30...N33, N83, N84) defective

- Check N30...N33, N83, N84
=> Page 24-83

Fuel pressure too low

- Check fuel pressure regulator
=> Page 24-73

Activated charcoal filter solenoid valve 1 (N80) sticking (permanently open)

- Check N80 , Final control diagnosis

Control limit not reached

Fuel pressure too high

- Check fuel pressure regulator
=> Page 24-73

Injector(s) (N30...N33, N83, N84) defective, leaking

- Check N30...N33, N83, N84
=> Page 24-83

1)     Only for Motronic with distributor

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00540

Knock sensor 2 -G66

Open circuit/short to earth

G66 defective

- Replace G66 => Page 28-4 , item 10

Wiring open circuit/short to earth in sensor wire to earth

- Check G66 => Page 28-16 , checking knock sensors

No knock recognition from Motronic control unit (J220)

- If necessary replace J220
=> Page 24-8 , item 2

00543

Maximum engine speed exceeded

Signal too large

Engine speed has reached governed speed (governor has cut-in)

- Erase fault memory
=> Page 01-13 , interrogating and erasing fault memory

Signal from engine speed sender (G28) disrupted
G28 sender wheel loose or defective

- Check G28 => Page 24-70

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00545

Engine/gearbox electrical connection

Short to earth

Wire has short to earth

- Locate and eliminate short circuit using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

00549

Consumption signal

Wiring short circuit to positive

- Locate short circuit according to current flow diagram and rectify:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Short circuit to positive

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00553

Air mass meter -G70

Open circuit/short to earth

G70 defective

- Replace G70 => Page 24-12 , item 8

Wiring open circuit/short to earth

- Check G70 => Page 24-32

Short to positive

Wire or G70 has short to positive

Unmetered air between G70 and engine

- Check intake air system for leaks
(unmetered air) => Page 24-75

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00561

Mixture adaption

Adaption limit
(add) exceeded

- Fuel tank empty
- Fuel pressure too low
- Fuel pump defective
- Wrong signal from air mass meter (G70)
- Unmetered air to G70

- Fill vehicle with petrol

Adaption limit
(mul) exceeded

- Lambda regulation faulty
- Leaks in the exhaust system to catalyst
- Activated charcoal filter solenoid valve (N80) sticking
- Injectors defective (coked, blocked)

- Check Lambda probe and Lambda regulation

Continued on next page

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00561

Mixture adaption

Adaption limit
(add) not reached

- Fuel pressure too high
- False signal from air mass meter (G70)
- Fuel in engine oil (short journeys)

- Check fuel pressure regulator
=> Page 24-32
Motorway drive for 15 min. or carry out oil change

Adaption limit
(mul) not reached

- Lambda regulation faulty
- Injector(s) defective (not closing fully)

- Check Lambda probe and Lambda regulation

Note on fault code 00561:

  • ◆ add = additive - The fault (e.g. unmetered air) has less effect as engine speed increases.
  • ◆ mul = multiplicative - The fault (e.g. injector fault) has more effect as the engine speed increases.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00577

Knock control Cyl. 1

Control limit exceeded

Fuel pressure not OK

- Check fuel pressure regulator
=> Page 24-73

Misfiring

- Check ignition part components
=> Page 28-20 1)

Intake air system leaking (unmetered air)

- Check intake air system for leaks (unmetered air) => Page 24-75

Injector(s) (N30...N33, N83 and N84) defective, leaking

- Check N30...N33, N83 and N84
=> Page 24-83

00578

Knock control Cyl. 2

- => Knock control Cyl. 1
Fault code 00577

- => Knock control Cyl.
Fault code 00577

1)     Only for Motronic with distributor

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00579

Knock control Cyl. 3

- => Knock control Cyl. 1
Fault code 00577

- => Knock control Cyl. 1
Fault code 00577

00580

Knock control Cyl. 4

- => Knock control Cyl. 1
Fault code 00577

- => Knock control Cyl. 1
Fault code 00577

00581

Knock control Cyl. 5

- => Knock control Cyl. 1
Fault code 00577

- => Knock control Cyl. 1
Fault code 00577

00582

Knock control Cyl. 6

- => Knock control Cyl. 1
Fault code 00577

- => Knock control Cyl. 1
Fault code 00577

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00609

Ignition output 1

Short circuit to positive in wiring or ignition transformer (N152)

Short circuit to positive

- Check N152 => Page 28-11

Short circuit to positive in wiring or ignition transformer output stage (N157)1)

- Check N152

00610

Ignition output 2

Short circuit to positive in wiring or ignition transformer (N152)

Short circuit to positive

- Check N152 => Page 28-11

00611

Ignition output 3

Short circuit to positive in wiring or ignition transformer (N152)

Short circuit to positive

- Check N152 => Page 28-11

1)     Only for Motronic with distributor

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00635

Lambda probe heating in front of catalyst

Open circuit/short to earth

Wiring open circuit/short to earth

- Check Lambda probe heating
=> Page 24-27

- Check wiring for short to earth:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

G39 defective

- Replace G39 => Page 24-9 , item 4

Short to positive

Wire has short to positive

- Check Lambda probe heating

- Check wiring for short to positive:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

G39 defective

- Replace G39 => Page 24-9 , item 4

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00640

Lambda probe heating relay
-J278

Wiring has short circuit to positive

- Check J278 => Page 01-53 , final control diagnosis

Short circuit to positive

- Locate short circuit according to current flow diagram and rectify:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Open circuit/short to earth

Wiring open circuit or short to earth

- Check wiring to J278
=> Current flow diagram, Electrical fault finding and Fitting locations binder

V.A.G 1551 print-out

Possible fault cause

Fault elimination

00668

System voltage terminal 30

Signal too low

Battery voltage below 10.0 V

- Check battery
=> Electrical system; Repair group 27;
=> Checking and charging battery

- Check Motronic control unit (J220) voltage supply
=> Page 24-112

After replacing the Motronic control unit J220
The fault is also displayed when the connectors are pulled off engine control unit.

- Perform basic setting
=> Page 01-13 , interrogate and erase fault memory

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01119

Gear recognition signal

Short to earth

Wire has short to earth

- Read measured value block:
=> Automatic gearbox 099;
=> Repair group 01; Self-diagnosis

Note on fault code 01119:

On vehicles with an automatic gearbox the engine control unit recognises whether the selector lever is in "P" or "N" or whether a gear is engaged via this signal.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01165

Throttle valve control part -J338

Fault in the basic setting

Accelerator cable incorrectly adjusted

- Check accelerator cable adjustment:
=> Repair group 20; Removing and installing parts of the fuel supply system; Servicing accelerator mechanism

Motronic control unit (J220) and/or throttle valve control unit (J338) has been replaced

- Perform basic setting
=> Page 24-120

01177

Control unit defective

Internal components in Motronic control unit (J220) defective
Possible attempted manipulation of software

- If necessary renew J220
, item 2

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01242

Control unit output stages

Loose wiring contacts to control elements or Motronic control unit (J220) defective

- Carry out final control diagnosis
=> Page 01-53

Mechanical fault

- Check wiring to control elements for loose contacts.
Renew J220 if necessary
=> Page 24-8 , item 2

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01247

Activated charcoal filter solenoid valve 1 -N80

Short to positive

N80 defective

- Check N80
=> Page 01-53 , final control diagnosis

Wiring or N80 has short to positive

Open circuit/short to earth

N80 defective

Wiring open circuit or short to earth

- Renew N80:
=> Repair group 20; Removing and installing parts of fuel supply system; servicing parts of activated charcoal filter system

Defective

N80 defective

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01249

Injector Cyl. 1 -N30

Short to positive

Wire or N30 has short to positive

- Check injectors
=> Page 01-53 , final control diagnosis

- Check injector wiring => Page 24-83 , checking injectors

Open circuit/short to earth

Wiring open circuit/short to earth

- Check injectors
=> Page 01-53 , final control diagnosis

- Check injector wiring => Page 24-83 , checking injectors

N30 defective

- If necessary replace appropriate injector => Page 24-81 , removing and installing injectors

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01250

Injector Cyl. 2 -N31

Short to positive

- => Injector Cyl. 1,
Fault code 01249

- => Injector Cyl. 1,
Fault code 01249

Open circuit/short to earth

01251

Injector Cyl. 3 -N32

Short to positive

- => Injector Cyl. 1,
Fault code 01249

- => Injector Cyl. 1,
Fault code 01249

Open circuit/short to earth

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01252

Injector Cyl. 4 -N33

Short to positive

- => Injector Cyl. 1,
Fault code 01249

- => Injector Cyl 1,
Fault code 01249

Open circuit/short to earth

01253

Injector Cyl. 5 -N83

Short to positive

- => Injector Cyl. 1,
Fault code 01249

- => Injector Cyl. 1,
Fault code 01249

Open circuit/short to earth

01254

Injector Cyl. 6 -N84

Short to positive

- => Injector Cyl. 1,
Fault code 01249

- => Injector Cyl. 1,
Fault code 01249

Open circuit/short to earth

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01257

Idling speed stabilization valve
-N71

Short circuit to positive in wiring or N71

- Check N71 => Page 01-53 , final control diagnosis

Short circuit to positive

Open circuit/short circuit to earth

Open circuit or short circuit to earth in wiring

N71 defective

- Renew N71 if necessary => Page 24-21 , item 18

V.A.G 1551 print-out

Possible fault cause

Fault elimination

01259

Fuel pump relay -J17

Short to positive

Wire has short to positive

- Locate and eliminate short using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

J17 defective

- If necessary replace J17:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Open circuit/short to earth

Wiring open circuit/short to earth

- Locate and eliminate short using current flow diagram:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

Note on fault code 01259:

If the fault "01259" is stored the faults "01247 and 01249...01254" could also be stored as these components are supplied with voltage via the fuel pump relay.

V.A.G 1551 print-out

Possible fault cause

Fault elimination

17978

Engine control unit blocked

Attempted manipulation

- Match the engine electronic control unit to the electronic immobilizer

Short in communication wire

- Check electronic immobilizer:
=> Electrical system; Repair group 96;
=> Servicing electronic immobilizer

Incorrect coding

Immobilizer control unit defective/not fitted

65535

Control unit defective

Component in Motronic control unit (J220)

- Renew J220 if necessary => Page 24-8 , item 2

Note to fault code 17978:

The control electronics for the immobilizer are located inside the dash panel insert and cannot be replaced separately.

If starting is attempted with a non-authorised key a statistical fault will be stored. After a subsequent start with an authorised key the fault will be converted to a sporadic fault.

Final control diagnosis > < Interrogating and erasing fault memory