Service Procedure

If any of these conditions exist, before vehicle is driven, check EPROM level and throttle angle setting (if EPROM level is below 4066) as follows:

- Connect VAG 1551 Scan Tool.

- Switch ignition ON (do not start engine).













Inner plenum panel cover, removing:





- Pull center cover (1) forward out of latch and remove from instrument panel (arrow).





- Remove screws (1).





- Lift left plenum panel cover (1) and remove from clips at front and rear edge.

- Pull cover (1) toward center of vehicle and out of retainer in A-pillar to remove.

- Lift right plenum panel cover (2) and remove from clips at front and rear edge.

- Pull cover (2) toward center of vehicle and out of retainer in A-pillar to remove.

- Remove mounting bolts from left closeout panel (3) and right closeout panel (4) and pull panels upward out of plenum to remove.

- Remove both A-pillar trim pieces.

- Remove screws (6) to allow removal of center defroster duct (5) and end pieces (7).

- Remove boot from defroster duct to center air distribution duct (arrow).

- Remove center defroster duct.





The control module (arrow) is located in the plenum chamber center right.

- Inspect TCM ground (GND) connection (must not be loose or corroded and terminal must be crimped on wire correctly).

Resistor wire, installing:





- Disconnect multi-pin connector from TCM.

- Cut tie wrap at end of connector and remove cover from connector by depressing tab with small screwdriver while pushing cover in direction of (arrow).





- Locate cavity 50 of TCM connector-arrow (cavity should be empty).





- Install electrical connector of resistor wire Part No. ZVW 311 100 into this cavity (50).

CAUTION!
Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.

- Remove enough tape to expose 125 mm (approx. 5 in.) wire harness.

- Locate gray/green wire (colors may vary) in cavity 16 of TCM connector (arrow).

- Follow wire from cavity 16 back into harness approx. 100 mm (4 in.), cut wire at this location.

- Strip insulation from both ends of wire.





- Route resistor wire along wiring harness to cut wire. Twist stripped end of resistor wire with end of gray/green (colors may vary) wire coming from harness.





- Discard buff-splice included with resistor wire kit and install appropriate buff splice from VAS 1978 wire repair kit and crimp using VAS 1978/1 crimping tool as shown.

- Crimp remaining end of gray/green (colors may vary) wire (from TCM connector end) into other end of butt-splice.





- Heat ends of wire splice using heat gun and VAS 1978/15 adapter per VAS 1978 Instructions.

- Re-tape wiring harness.

- Reinstall TCM connector cover and install new tie-wrap.

- Reinstall connector onto TCM.

- Reinstall defroster duct, boot and all plenum covers in reverse order of removal.
- Verify throttle angle setting using Function 08 display group 001 page 1 (IMPORTANT! kickdown switch activation must be verified during throttle angle setting).