Engine Controls - MIL ON/Throttle Valve DTC's In ECM
MIL on (DTCs for throttle valve in ECM)97 08 05 2018260/2 September 4, 2008. Supersedes Technical Service Bulletin Group 97 number 08-04 dated August 12, 2008 so title conforms to naming conventions.
Condition
- MIL on.
- A number of incident memory entries with regard to the throttle valve are stored in the ECM. In most cases, the entries are sporadic. The most frequent incident memory entries are:
- P1545 (throttle control malfunction).
- P0121 (throttle potentiometer - G69 implausible signal).
- P0123 (throttle potentiometer - G69 signal too big).
- P0221 (angle transmitter 2 for throttle actuator G188 implausible signal).
- P0222 (angle transmitter 2 for throttle actuator G188 signal too small).
Technical Background
Contact resistance in the ECM wiring - throttle valve.
Production Solution
Optimized wiring and contacts.
Service
Wiring Harness and Connector Repairs, General Information
- Observe general notes for repairs on the vehicle electrical system chapter of the repair manual. (See Repair Manual >> Electrical System >> Electrical Equipment General Information >> Wiring 97.)
- For repairs on vehicle electrical system, soldering is not permitted.
- Do not repair crimp connectors. If necessary, lay a wire parallel to the inoperative wire.
- After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Yellow wires are to be used exclusively for wiring harness repairs.
- Mark repaired areas using yellow adhesive tape.
- Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed repair.
- Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.
Procedure
1. With the ignition switched off, disconnect battery ground (GND) cable. (See Repair Manual >> Electrical Equipment >> Repair Group 27 >> Battery.) Disconnecting battery ground wire is necessary to work safely on the vehicle electrical system.
Warning: The above step must be completed to ensure safety during the repair. Also, observe all country-specific regulations.
2. Use the applicable repair manual in Elsa in addition to the description below. Check ETKA to determine if you need set 1 or set 2.
3. Lengthen wires and preassemble seals according to Figure 1.
4. On the new housing, remove pink lock with small flathead screwdriver. Use slot marked in Figure 2.
5. Insert all terminals into housing until they audibly click.
6. Reinstall pink lock.
7. Using the appropriate assembly tool, slide the single wire seal up the repair wire until it contacts the housing. Continue to slide the single wire seal into the housing as far as the stop (Figure 3).
8. Strip wires 6-7 mm using tool VAS 1978/3. Install crimp connectors using crimping pliers (base tool) -VAS 1978/1-2 with the head VAS 1978/1-1 (Figure 4).
9. Remove car harness insulation to the appropriate length (approximately 24 cm).
10. Lay new harness beside the old harness. Cut original wires to fit the new harness.
11. Twist wires 3 and 5 and 1, 2, 4 and 6 as they were originally.
12. Crimp connections.
13. Use shrink tip for hot air gun (VAS 1978/15) with hot air gun 220 V/50 Hz (VAS 1978/14) to shrink the shrink tubes.
NOTE: When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
Always observe operating instructions of heat gun.
14. Re-insulate harness with yellow tape.
15. Check proper function. If necessary, check DTC memory, erase and/or bring systems into basic setting.
NOTE: Only if faults reoccur after the repair is the main throttle allowed to be replaced.
Warranty
When procedure applies to vehicles under warranty, use the following:
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual. Claims are subject to review or audit by Audi Warranty.
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.