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 Output Diagnostic Test Mode (DTM) MUST BE DONE before erasing of stored codes is possible. Follow all steps exactly and complete entire procedure.

OUTPUT DIAGNOSTIC TEST MODE
Output Diagnostic Test Mode is provided to check the mechanical motion and the electrical wiring of certain actuators.

The actuators are checked acoustically or by touch. In some cases, it might be necessary to use an LED tester for the fuel injectors, as the clicking sound from the injectors is very soft and short. Avoid background noise during audible check of the injectors.

When an audible "click" is heard from the actuator being tested, this only confirms that there is electrical current to the actuator and that the component is operating mechanically. The audible noise does not guarantee perfect component operation. Additional testing may be necessary.

This function can only be carried out with the engine OFF (not running) and the ignition switch turned ON. The ignition switch should remain ON throughout entire test. The DTM will be interrupted if the engine is started or if an engine speed pulse is detected.

COMPONENT BLINK CODE AND ACTIVATION SEQUENCE
During the Output Diagnostic Test Mode, each component is activated in specific order. This is known as the Component Activation Sequence. The Blink Code for the component and the activation sequence is as follows.

4411 Fuel injector 1 (N 30)
4412 Fuel injector 2 (N 31)
4413 Fuel injector 3 (N 32)
4414 Fuel injector 4 (N 33)
4421 Fuel injector 5 (N 83)
4422 Fuel injector 6 (N 84)
4431 Idle Air Control (IAC) valve (N 71)
4343 EVAP Canister Purge Regulator valve (N 80)
3434 Heated Oxygen Sensor (HO2S) Relay (J 278)
4312 EGR Vacuum Regulator Solenoid valve (N 18) *
XXXX Ignore display.Not applicable to this vehicle.
4311 Secondary Air Injection pump relay (J 299)
4313 Secondary Air Injection solenoid valve (N 112)

EXAMPLE:
- Under normal circumstances, the Engine Control Module (ECM) will begin DTM component activation sequence with activation of Fuel Injector # 1, followed by Injectors # 2, # 3, # 4, etc. as shown in sequence list above.
- Engine Control Module will activate the Idle Air Control Valve (IACV) after the Fuel Injectors.
- ECM will activate the EVAP Canister Purge Regulator valve after the Idle Air Control Valve.
- ECM will activate the Heated Oxygen Sensor (HO2S) Control Relay after the EVAP Canister Purge Regulator valve and so on. The component activation sequence NEVER changes.

OTHER POSSIBILITIES
- ECM does not automatically begin with the first component listed on the activation sequence (in this case first component is Fuel Injector for cylinder # 1).
- It is possible to stop and exit the Output Diagnostic Test Mode mid-way through the component activation sequence.
- When this occurs, the last component being activated will be stored in the ECM. THAT COMPONENT will be the first to be activated NEXT TIME the Output Diagnostic Test Mode is started.

NON-EXISTING COMPONENTS
- The EGR Vacuum Regulator Solenoid Valve is only installed on California emissions equipped vehicles, but will always be displayed/activated in sequence during DTM checking, even if not installed on the vehicle.
- There is also a non-existing component with unknown component code that will be activated 11th in sequence during DTM checking. At present, no component has been assigned to this sequence position. Just like the EGR frequency valve, a component code display/activation will be given whether or not that component is actually installed on the vehicle.

OUTPUT DIAGNOSTIC TEST MODE REQUIREMENTS AND SET-UP
1. Turn ignition switch OFF.
2. Battery voltage must be GOOD (at least 11.5 volts).
3. Fuse # 22 in fuse/relay panel must be GOOD.
4. Ground connections on engine and transmission must be GOOD (grounds located below lower part of intake manifold).

DLC Location Passat:

5. Remove access panel for Data Link Connector by carefully prying trim panel off below instrument cluster to the right of the steering.

16-Pin Data Link Connector Pin Source I.D. And Location:

6. Check voltage at 16-Pin data link connector and note polarity of terminals. Polarity MUST be as shown. If not, repair as needed before proceding.
7. The Malfunction Indicator Lamp, located 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.

OBD 1 Adaptor:

OBD1 Adaptor Location under rear seat bench:

Output Diagnostic Test Mode can be achieved using the OBD1 ADAPTOR provided with the vehicle (see image). Most cars were shipped with one under the rear seat (see image), if not, an adaptor MAY be obtained from the dealer. If OBD1 adaptor is not available, use self-made jumper wire assembly described below.

Self-made Jumper Wire With Soldered Ends:

Output Diagnostic Test Mode 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 OBD1 adaptor described above, are used in the same manner throughout this procedure and will give identical results.

9. If self-made jumper wire is being used GO TO STEP 10.

Jumper Wire To 16-Pin DLC Hookup, Jetta Shown:

10. If using JUMPER WIRE, insert jumper wire connector "W1" into DLC terminal #4 and jumper wire connector "W2" into DLC terminal #15 as shown.

- DO NOT JOIN CONNECTORS J1 and J2 AT THIS TIME.

DIAGNOSTIC TEST MODE ACTIVATION PROCEDURE
1. Connect OBD1 adaptor to 16-Pin DLC, or if jumper wire is being used, join together jumper connectors J1 and J2.
2. Turn ignition switch ON.

- MIL in the dash must light up.
- IF NOT:
^ Check if ignition switch is ON.
^ Check jumper connections.
^ Check wires from DLC to the Motronic ECM.

16-Pin Data Link Connector And Jumper Wire, Jetta Shown:

3. After approx. 4 seconds, remove OBD1 adaptor or separate jumper connectors J1 and J2 (reverse of step 1).

- MIL should begin flashing a component blink code.
- Component will activate (click).

4. Verify starting point of component activation sequence (should start with injector # 1). Count and record component blink code as it is displayed on the MIL, refer to component activation sequence for component blink code I.D.

- Injector code Is Displayed:
4411 Fuel injector 1 (N 30)
^ GO TO STEP 5.

- Injector code IS NOT DISPLAYED:
^ Join jumper connectors for 4 seconds then separate.
^ Continue this process until code 0000 is displayed by MIL.
^ After code 0000 is displayed, turn ignition switch OFF for at least 30 seconds and restart Output Diagnostic Test Mode to get Injector blink code.
^ 4411 Fuel injector 1 (N 30)

- Activate fuel injector for cylinder No. 1 (N 30) from engine compartment by manually opening and closeing the throttle valve once.

NOTE:
- Fuel injector No. 1 must click. Fuel injectors click very quietly.

- If one or more injectors does NOT click, check test procedures under individual component.

- To activate fuel injectors for cylinders 2 to 6, re-open and then close the throttle valve once for each injector.

NOTE: To select the next check or to skip an individual check, connect the jumper connectors for at least 4 seconds then separate.

- To activate IAC valve (N 71), connect OBD1 adaptor to 16-Pin DLC, or the jumper connectors for at least 4 seconds, then separate blink code will indicate the next component checked.

4431 Idle Air Control valve (N 71)

The IAC valve must switch on and off until the next component is selected.
If valve does not operate, check test procedures under individual component.

- To activate EVAP Canister Purge Regulator valve (N 80), connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate. Blink code will indicate the next component checked.

4343 EVAP Canister Purge Regulator valve (N 80)

NOTE:
- The N80 valve must click until the next component is selected.

- If solenoid valve does NOT click, check test procedures under individual component.

- While Output DTM is activated, disconnect hose from N 80 valve (coming from carbon canister), attach auxiliary hose to N 80 valve, blow into hose. N 80 valve must open and close.
- To activate Heated Oxygen Sensor relay (J 278), connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate. Blink code will indicate the next component checked.

3434 Heated Oxygen Sensor Relay (J 278)

NOTE:
- The Heated Oxygen Sensor relay must click until the next Output DTM is selected.

- If relay does NOT click, check test procedures under individual component.

- To activate EGR Vacuum Regulator Solenoid valve (N 18), connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate. Blink code will indicate the next component checked.

4312 EGR Vacuum Regulator Solenoid valve (N 18)

NOTE:
- Not all vehicles have EGR, but it is necessary to activate the code to clear the DTC memory.

- The N 18 valve must click until the next Output DTM is selected.

- If N 18 valve does NOT click, check test procedures under individual component.

- There is a non-existing component with unknown component code that will be activated 11th in sequence during DTM checking. It is necessary to activate the code to clear the DTC memory.

- To activate the non-existing component, connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate, a blink code will indicate the non-existing component.

No component has been assigned to this position of the component activation sequence.

- To activate Secondary Air Injection pump relay (J 299), connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate. Blink code will indicate the next component checked.

4311 Secondary Air Injection pump relay (J 299)

NOTE:
- The J 299 relay must operate the Secondary Air Injection pump until the next Output DTM is selected.

- If Secondary Air Injection pump does NOT operate, check test procedures under individual component.

- To activate Secondary Air Injection solenoid valve (N 112), connect OBD1 adaptor to 16-Pin DLC or the jumper connectors for at least 4 seconds then separate. Blink code will indicate the next component checked.

4313 Secondary Air Injection solenoid valve (N 112)

NOTE: The N 112 valve must click until the Output DTM is ended and memory cleared.

CLEARING DIAGNOSTIC TROUBLE CODE MEMORY
1. Once all components have been successfully checked, connect OBD1 adaptor to 16-Pin DLC or the jumper connectors together for at least 4 seconds then separate as before until code 0000 (end of output) is displayed on the MIL.

- Code 0000 display --- 2.5 second flash (zero) at 2.5 second intervals.
- TO CLEAR DTC MEMORY, GO TO STEP 3.

2. After display of code 0000 has been achieved, the DTC memory may be cleared. If you do not want to erase the DTC memory, or wish to view the stored codes again, turn the ignition switch OFF.

However, to clear the codes stored in DTC memory AFTER the ignition has been turned OFF, you must once again complete BOTH trouble code display and diagnostic test mode procedures before the codes can be erased.

3. After display of code 0000 has been achieved, the DTC memory may be cleared by once again connecting the jumper connectors together for at least 4 seconds then separate. The DTC memory IS NOW CLEAR.
4. After clearing the DTC memory, test drive vehicle for at least 10 minutes (minimum), during the test drive.

- Coolant temperature must be over 176°F (80°C) for at least 3 minutes.
- With engine speed over 4600 RPM, press gas pedal briefly all the way down.
- With trans in 4th gear, starting from approx. 30 MPH, accelerate for about 4 seconds with gas pedal pushed halfway down.

5. Activate DTC trouble code display with engine RUNNING to ensure no new codes have been generated. If no new codes are present, code 4444 will display to confirm and no further action is necessary.
6. Refer to Without VAG 1551- Reading OBD, for procedure.