Engine Controls - Hard Start/Exhaust Smoke/Runs Rough
01 07 44May 7, 2007
2010463 Supersedes T.B. Group 97 number 05-04 dated July 1, 2005 due to removal of RVU referral, reprogramming ECM using Software Version Management (SVM) and inclusion into ElsaWeb.
Vehicle Information
Condition
Update Programming, Hard Starting (Extended Cranking Required) or No Start When Wet, Runs Rough On Initial Start, May Be Accompanied By Light Gray Smoke
Tip:
Procedure is ONLY valid in vehicles with Software level below 6328.
Technical Background
Hard start, extended cranking, no start when wet (P0321 may be stored in DTC memory). May also be accompanied by rough running and smoking.
Updated ECM software that addresses:
Production Solution
Software update and wiring repair.
Service
Vehicle requirements
Battery MUST have minimum no-load charge of 12.5V (failure to maintain voltage during update process can lead to ECM failure) (use an approved battery charger 1NC940 to maintain battery voltage).
VAS 5051: connected to vehicle and to 110V AC Power supply at all times during procedure.
VAS 5052: connected to vehicle with battery voltage requirements met.
Any appliances with high electromagnetic radiation (i.e. mobile phones) switched OFF.
When performing the update programming procedure, ALL DTCs for all systems are erased.
DTCs linked to Guided Fault Finding function tests will be lost. Therefore, always address stored DTCs for Customer concerns unrelated to the update programming procedure first.
PROCEDURE:
Engine Control Module Update - Programming (Flashing) using Software Version Management (SVM)
Tip:
The SVM Process must be completed in its entirety so the database receives the update confirmation response. A warranty claim may not be reimbursed if there is no confirmation response to support the claim. For further update instructions and troubleshooting, refer to SVM Technical Bulletin Instance 2014603, in ElsaWeb.
^ Update the Engine Control Module using the SVM Unit code as listed in the table shown.
^ If the vehicle has a tuned ECM Or TCM, ensure the Control Module Tuning Form has been filled out.
Note:
An Update Programming procedure (flash) may overwrite any "TUNED" ECM or TCM programming. A "TUNED" ECM or TCM is described as any ECM or TCM altered so as to perform outside the normal parameters and specifications approved by Volkswagen of America, Inc.
Current Tuned ECM or TCM requirements: If you encounter a vehicle with a "Tuned" ECM or TCM, your dealership must do the following before performing any procedure that updates ECM or TCM programming:
^ Notify the owner that their ECM or TCM was found to have been tuned
^ Notify the owner any damage caused by the tuning of the ECM or TCM (including any adverse emissions consequences) will not be covered by Volkswagen of America, Inc. warranties.
^ Obtain the owners written consent (see Control Module Tuning form) for any requested repair under warranty or outside warranty that requires flashing, which will automatically overwrite the Tuned" program.
^ Reset readiness code.
^ Continue to Secondary Ground Installation
Secondary Ground Installation
Install secondary ground repair wire to Control Module -J248- as follows:
^ Obtain radio code and preset radio stations.
^ Disconnect battery ground (GND) strap.
^ Remove plenum chamber center cover -black arrow- in direction of -white arrow-.
^ Remove screws -black arrows- and left plenum chamber cover -white arrow-.
^ Remove plenum chamber inner cover.
^ Remove pushpins holding wiring harness -arrows-.
^ Remove Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- from mounting bracket.
^ Remove T60 (60 pin) connector from Diesel Direct Fuel Injection (DFI) Engine Control Module (ECM) -J248- in plenum chamber.
^ Remove insulating tape from connector to ground wire to expose small 3 wire splice -arrow-.
^ Remove covering from splice.
^ Separate three spliced wires.
^ Strip insulation on all wire ends approximately 6-7 mm (1/4 inch).
^ Splice white wire from engine speed sensor (G28) to black wire from ECM pin T60143 as shown using red butt connector Part No: 111 971 940A -black arrow-.
^ Install red butt connector Part No: 111 971 940A to remaining wire - white arrow-.
^ Crimp remaining splice using appropriate crimping tool from VAS 1978A Repair kit.
^ Disassemble ECM connector including removal of violet secondary lock.
^ Remove plug from cavity 57 of T60 connector.
^ Insert terminal of repair wire Part No: 000 979 009 into cavity 57 of T60 connector.
^ Route repair wire to open side of butt connector (arrow) on black shield wire (coming from engine speed sensor) and cut repair wire to length.
^ Crimp each splice using appropriate crimping tool from VAS 1978A Repair kit.
With repair wires crimped:
^ Apply Electric Hot Air Blower VAS 1978/14 and Adapter for Heat Gun VAS 1978/15 to shrink and seal butt connector.
Tip:
Connector must be heated by moving adapter tip from center outward until fully sealed.
^ Re-tape exposed wiring and reassemble ECM connector.
^ Reinstall secondary locks (previously removed).
^ Reassemble connector and cover using a new cable-tie.
^ Reinstall connector onto ECM.
With overlay wire completely installed:
^ Install ECM into mounting bracket.
^ Install wiring harness push pins.
^ Install plenum chamber inner cover.
^ Install left-hand plenum chamber cover.
^ Install plenum chamber center cover.
^ Connect battery ground (GND) strap.
Warranty
* Code per warranty vendor code policy.
Required Parts and Tools
No Special Parts required.
No Special Tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.