Without Scan Tool
NOTE: Read entire procedure before beginning. View images as corresponding text is read to ensure all steps and results are clearly understood. Display of Diagnostic Trouble Codes (DTC) AND completion of the Diagnostic Test Mode (DTM) MUST be done before it is possible to erase stored codes. Follow all steps exactly and complete entire procedure.ON-BOARD DIAGNOSTICS -- ACCESS INFORMATION
A Volkswagen VAG 1551 scanner is recommended to access the On Board Diagnostics (OBD) and display Diagnostic Trouble Codes. Unfortunately the VAG 1551 is expensive and not readily available to most shops. With this in mind, the procedure below has been written assuming a VAG 1551 WILL NOT be used.
An alternate procedure to access the OBD and display Diagnostic Trouble Codes is available. The alternate method uses the Malfunction Indicator Lamp (MIL) to display the Diagnostic Trouble Codes. Trouble codes are displayed as light flash pulses from the MIL (flash pulses are also known as "blink codes" or "flash codes"). To initiate trouble code output, first connect the jumper cable OR self-made jumper wire (both described below) to specific terminals of the Diagnostic Link Connectors (DLC). Once the jumper is properly connected to the DLCs, a timed connect-disconnect procedure with the jumper will start the DTC display. Erasing trouble codes and initiation of the Diagnostic Test Mode is done using the jumper wire assembly as well.
By correctly and completely following all steps of this procedure, a qualified technician can successfully access the Motronic system's On-Board Diagnostics. The data collected will be as accurate and reliable as data received through a scanner.
Jumper Cable Assembly:
Diagnostic Trouble Code display can be achieved using the JUMPER CABLE ASSEMBLY provided with the vehicle (see image). Most cars were shipped with one in the trunk or glove box, if not, jumper cable #357 971 514E may be obtained from the dealer. If cable is not available, use self-made jumper wire assembly described below.
Self-made Jumper Wire With 1/8" Wide Blade Ends:
Trouble Code display can also be achieved using a SELF-MADE JUMPER WIRE ASSEMBLY (see image) which can be constructed from readily available electrical connectors. The jumper wire shown here and the jumper cable described above are used in the same manner throughout this procedure and will give identical results.
TROUBLE CODE DISPLAY REQUIREMENTS AND SETUP
1. Battery voltage must be GOOD (at least 11.5 volts).
2. Fuse #22 in fuse/relay panel must be GOOD.
3. Ground connections on engine and transmission must be GOOD (grounds located below lower part of intake manifold).
Data Link Connector Access:
4. Remove access panels for Data Link Connectors by carefully prying off with screwdriver (panels located under heating/ventilation controls).
Data Link Connector Terminal Identification:
5. Check voltage at BLACK data link connector "A" and note polarity of terminals. Polarity MUST be as shown, if not, repair as needed before proceding.
6. The Malfunction Indicator Lamp in the instrument panel, MUST light up when the ignition is switched ON and go OFF when the engine is shut OFF. If a DTC is stored in memory, the MIL lights even with the engine RUNNING but will shut OFF when engine is shut OFF.
Data Link Connectors And Jumper Cable:
7. If using JUMPER CABLE, connect BLACK jumper cable connector to BLACK DLC connector.
^ DO NOT CONNECT THE WHITE CONNECTORS AT THIS TIME.
^ If self-made jumper wire is being used, proceed to step 8.
Jumper Wire To DLC Hookup:
8. If using JUMPER WIRE, insert jumper wire blade connector "B1" into BLACK DLC terminal #1 and jumper wire blade connector "B2" into WHITE DLC terminal #1 as shown.
^ DO NOT JOIN CONNECTORS "J1" and "J2" AT THIS TIME.
NOTE:
- There are two different trouble code display procedures.
- The DTC display procedure should be completed with ENGINE RUNNING if possible. If engine does not RUN or will not START, proceed to ENGINE DOES NOT RUN display procedure which is directly after the ENGINE RUNNING procedure.
- "ENGINE RUNNING" procedure is different from "ENGINE DOES NOT RUN" procedure.
ENGINE RUNNING DISPLAY PROCEDURE
1. Start engine and let idle (1300 rpm maximum).
2. With engine RUNNING, join WHITE jumper cable connector to WHITE DLC connector. If using jumper wire join connectors J1 and J2 together.
- MIL in dash MUST light up.
^ IF NOT:
^ Check wires from DLC to the Motronic ECM for open.
^ Check jumper connections.
Data Link Connectors And Jumper Wire:
3. After approx. 4 seconds, disconnect WHITE jumper connector from WHITE DLC or separate jumper wire connectors J1 and J2 (reverse of step 2).
^ MIL will go OFF, come ON for 2.5 seconds, go OFF.
^ This confirms display signal has been received.
^ MIL will then display (flash) trouble code pulse groups.
^ Converting pulse groups to trouble codes found in Step 5.
4. Count MIL flashes and record flash pulse groups as they display from the MIL.
^ Only one trouble code will display per activation (same code repeats).
Reading Fault Codes:
5. Each blink code is comprised of 4 flash pulse groups with a maximum of 4 flashes per group. Compile the number of flashes in each of the 4 pulse groups to determine the 4 digit code being displayed.
6. If no codes are present, code 4444 will display and no further action is necessary.
7. If codes other than 4444 are present, repeat display activation steps 2 and 3 until all codes are displayed.
8. Once all trouble codes have been displayed, code 0000 (end of trouble code output) will display.
^ Code 0000 display --- 2.5 second flash (meaning number zero) at 2.5 second intervals.
NOTE: If the key is turned OFF at any time before code 0000 is displayed, trouble codes WILL NOT be cleared, and you will need to perform reset procedure again.
9. All stored trouble codes should now be cleared.
10. Refer to DIAGNOSTIC CHARTS for explanation of trouble codes (called blink codes on chart). Testing and Inspection
ENGINE DOES NOT RUN DISPLAY PROCEDURE
1. Crank engine for 5 to 6 seconds, leave ignition switch ON after cranking. Ignition switch MUST BE LEFT ON after cranking for the entire procedure, failure to do so makes test invalid.
CAUTION: To avoid overheating starter motor, DO NOT crank engine for longer than 15 seconds.
2. With ignition ON, connect WHITE jumper cable connector to WHITE DLC connector. If using jumper wire, join jumper connectors "J1" and "J2" together.
- MIL in the dash MUST light up.
^ IF NOT:
^ Check wires from DLC to the Motronic ECM for open.
^ Check jumper connections.
Data Link Connectors And Jumper Wire:
3. After approx. 4 seconds disconnect WHITE jumper connector from WHITE DLC or separate jumper connectors J1 and J2 (reverse of step 2).
^ MIL will go OFF, come ON for 2.5 seconds, go OFF.
^ This confirms display signal has been received.
^ MIL will then display (flash) trouble code pulse groups.
^ Converting pulse groups to trouble codes found in Step 5.
4. Count MIL flashes and record flash pulse groups as they display from the MIL.
^ Only one trouble code will display per activation (same code repeats).
Reading Fault Codes:
5. Each blink code is comprised of 4 flash pulse groups with a maximum of 4 flashes per group. Compile the number of flashes in each of the 4 groups to determine the 4 digit code being displayed.
6. Code 2111 and/or 2113 should be displayed.
NOTE:
- Code 2111 (Engine Speed Sensor) and/or code 2113 (Camshaft Position Sensor) should always be displayed when ignition switch is ON and engine is NOT RUNNING. This fault display is normal and can be ignored when displaying trouble codes with engine NOT RUNNING.
- However, if the Engine Speed Sensor or Camshaft Position Sensor are suspected of causing the NO START CONDITION, they should be tested before continuing, refer to ECM Pinout Tests perform test step 21 (for Camshaft Position Sensor) and 27 (Engine Speed Sensor).
7. Repeat display activation, steps 2 and 3 to display next code as only one code will be displayed for each activation.
8. Continue repeating steps 2 and 3 until code 0000 (end of trouble code output) is displayed.
^ Code 0000 display --- 2.5 second flash (meaning number zero) at 2.5 second intervals.
NOTE: If the key is turned OFF before code 0000 is displayed, trouble codes WILL NOT be cleared, and you will need to perform reset procedure again.
9. All stored trouble codes should now be cleared.
10. Refer to DIAGNOSTIC CHARTS for explanation of trouble codes (called blink codes on chart). Testing and Inspection