Volkswagen Golf 4 1999, Golf 4 2002, Golf 4 2000, Golf 4 2001, Golf 4 2004 Service Manual
...
Note:
For Guided Fault Finding information, refer to VAS 5051 Diagnostic Tester
01 - On Board Diagnostic (OBD)
ABS ITT Mark 20 IE On Board Diagnostic (OBD)
Function
Identifying characteristics
Technical data
Safety precautions
On Board Diagnostic (OBD) with V.A.G 1551 Scan Tool or Tester VAS 5051 (flow chart)
Electrical/electronic components and locations
Diagnostic Trouble Codes (DTC) displayed by warning lights
-K14-, -K47- and -K118-
ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
V.A.G 1551 Scan Tool, connecting and selecting function
Diagnostic Trouble Code (DTC), memory
Automatic test sequence
Vehicle Diagnosis, Testing and Information System VAS 5051, connecting and se lecting ABS
control module
Diagnostic Trouble Code (DTC) table
Diagnostic Trouble Code (DTC) memory, erasing and ending output
ABS control module, coding
Measured value block, reading
Safety precautions
Output Diagnostic Test Mode (DTM)
Basic setting, initiating
ABS, ABS/EDL and ABS/EDL/ASR ITT Mark 20 IE, electrical check
Multi
-pin connector with contact assignment
Test table
Brake light switch, adjusting
ABS Mark 60 On Board Diagnostic (OBD), vehicles from my 10.00
Function
Arrangement of ABS MARK 60
Technical data
Safety precautions and fundamental points regarding troubleshooting
Troubleshooting with V.A.G 1551 scan tool or tester VAS 5051 on ABS Mark 60 (flow chart)
Electrical/electronic components and installing locations
Diagnostic Trouble Codes (DTCs) displayed by warning lights
-K47-, -K118- and -K155-
On Board Diagnostic (OBD), performing
Test prerequisites for OBD
Safety precautions
Scan tool, connecting
V.A.G 1551 scan tool, connecting and selecting function
List of selectable functions
Automatic test sequence
Diagnostic Trouble Code (DTC) memory, checking
Output Diagnosic Test Mode (DTM)
Diagnostic Trouble Code (DTC) table
Diagnostic Trouble Code (DTC) memory, erasing and ending output
ABS control module, coding
Vehicle data label
Measured value block, reading
Output Diagnosic Test Mode (DTM)
Basic setting, initiating
Login procedure
Electrical check of Mark 60
Multi
-pin connector with contact assignments
Test table (test steps 1
- 16)
Test table (test steps 17
- 23)
Definitions
Volkswagen Golf 4 / Bora (1998-2005), GTI / Jetta (1998-2005), R32
(A4)
01-1
ABS ITT Mark 20 IE On Board
Diagnostic (OBD)
Function
Since the control modules are interconnected
with CAN-bus, always begin OBD by checking
the Diagnostic Trouble Code (DTC) memories
of all the control modules in the vehicle.
This occurs in the Automatic test sequence and
is activated with key function 00.
When doing this, check to see if there are
DTCs stored which may influence the ABS.
On Board Diagnostic (OBD) relates to the
electrical/electronic part of the ABS, i.e. only
malfunctions via the electrical connection to the
control module are recognized (e.g. speed
sensor open circuit).
The 25-pin ABS Control Module (w/EDL) -J104-
forms with the hydraulic unit a compact unit.
The unit is located on the left in the engine
compartment. The control module is equipped
with a DTC memory. The diagnostic connection
is located in the center console below the
heating/air conditioning controls.
The control module recognizes malfunctions
during vehicle operation and stores them in a
permanent memory, the contents of which
remain even during periods of no battery
voltage.
Стр. 1 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-2
Sporadic (isolated) malfunctions will also be
recognized and stored. But if these malfunctions
do not occur again within the next 50 vehicle
starts and driving off sequences then, with the
exception of "control module inoperative", the
DTC memory will be erased.
After switching on the ignition and/or starting the
engine the ABS warning light -K47- and the
warning light for brake system -K118- light up for
approx. 2 seconds.
During this period a test sequence (self-check) is
run in the control module for the following
functions:
To check if the supply voltage is at least 10.0
Volt
To check control module including the valve
windings
To check the coding of the control module
A static check of the speed sensor (no speed
signal)
If after driving off and exceeding a speed of
approx. 20 km/h (approx. 13 mph) the speed
signal is not OK. The ABS warning light -K47will light up again.
Стр. 2 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-3
V.A.G 1551 Scan Tool or tester VAS 5051
The On Board Diagnostic (OBD) must be
initiated always at the commencement of
troubleshooting. Electrical malfunctions which
influence the braking characteristics will be
stored. They can be checked with the V.A.G
1551 Scan Tool or with the tester VAS 5051.
The information displayed is used in
conjunction with a DTC table which has
information on the possible DTC causes for
repair measures.
Стр. 3 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-4
Identifying characteristics
The brake booster boost is produced by
vacuum pressure.
Distinguishing features:
1 - 10" brake booster
2 - Hydraulic unit
3 - Control module, 25-pin (bolted to
hydraulic unit)
Distinguishing features of ABS,
ABS/EDL and ABS/EDL/ASR ITT Mark 20
IE hydraulic unit
Dimension -A- 100 mm vehicles with
ABS
Dimension -A- 130 mm vehicles with
ABS/EDL
Dimension -A- 130 mm vehicles with
ABS/EDL/ASR
Стр. 4 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-5
Technical data
Control module identification
The control module version is displayed when
the V.A.G 1551 Scan Tool or the tester VAS
5051 is connected and the control module for
brake electronics is selected Page 01-23 .
1J0 907 379 D / G - ABS
1J0 907 379 E / H - ABS/EDL
1J0 907 379 R / J - ABS/EDL/ASR
Diagnostic Trouble Code (DTC) memory
A non-volatile memory ensures that the
contents of the DTC memory are retained even
without a voltage supply.
Data outputis achieved in operating mode 1
(rapid data transfer).
Стр. 5 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-6
Safety precautions
The ABS is a vehicle safety system; the
appropriate knowledge is necessary to work on
the system.
In order to check complaints and to be able to
carry out pin-pointed troubleshooting, the
Diagnostic Trouble Code (DTC) memory must
be checked before beginning work on the ABS
system.
Only separate connectors when the ignition is
switched off.
Observe the appropriate instructions regarding
the handling of brake fluid.
Repair Manual, Brake System, Repair Group
47
ABS malfunctions are indicated by the ABS
warning light illuminating. Certain malfunctions
will only be recognized at speeds above 20
km/h (approx. 13 mph) (carry out road test).
If the ABS Warning Light -K47- and the warning
light for brake system -K118- do not light up,
but the brake system is not functioning correctly
then the malfunction must be sought in the
conventional braking system.
Repair Manual, Brake System; Repair Group
45
Стр. 6 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-7
On Board Diagnostic (OBD) with V.A.G 1551 Scan Tool or Tester VAS 5051
(flow chart)
Connect V.A.G 1551 and select 1-rapid
datatransfer
or
Connect tester
VAS 5051 and
select vehicle OBD
Compare control
module identification
Select address word 03-Brake
electronics
Check DTC memory
02
Repair DTCs using DTC table No DTCs
recognized
Read measured
value block 08
Perform output Diagnostic
Test Mode (DTM) 03
Replace
component
1. Perform test drive at more than
20 km/h
2. Check DTC memory 02 again
3. "No DTCs recognized" is
displayed again
A B C
D
E
Стр. 7 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
01-8
A B
C
D
E
Perform directed
entry of electrical
tests
Service
hydraulic/mechanical
parts of brake system (
Repair Manual)
1. Perform all test steps
of electrical checks
Page 01-102
Identification not OK.
2. Service
hydraulic/mechanical
parts of brake system
( Workshop
Manual)
Replace control module
- Connect V.A.G 1551 and check DTC memory again (02).
- Erase DTC memory (05)
- Perform test drive at more than 20 km/h (13 mph) and allow the ABS to
regulate braking.
- Check DTC memory again after test drive. If "No DTC recognized" appears
on display of V.A.G 1551 after repairing DTCs and performing test drive the On
Board Diagnostic (OBD) is completed.
Стр. 8 из 8ABS ITT Mark 20 IE On Board Diagnostic (OBD
)
Electrical/electr
o
components an
d
locations
Repair Manual, Brake
System, Repair Group 45
1 - ABS hydraulic unit
N55-
Located on left of
engine compartm
e
The ABS hydrauli
c
pump -V64- and t
h
inlet/outlet valves
i
hydraulic unit are
checked by On B
o
Diagnostic (OBD)
The ABS Hydrauli
c
Pump -V64- and
v
block must not be
separated from o
n
another
Removing and
installing:
When changing th
hydraulic unit, alw
a
seal the old part
w
the plugs from the
repair set Part No.
698 311 A
Стр. 1 из 14Electrical/electronic components and locations
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01-10
2 - ABS control
module
(w/EDL) J104-
Location: on
hydraulic unit
on left of
engine
compartment
Checked by
On Board
Diagnostic
(OBD)
Checking the
multi-pin
connector to
control
module
Page 01-106
Do not
disconnect
connector
before
successfully
completing
OBD. Switch
ignition off
before
separating
connection.
Стр. 2 из 14Electrical/electronic components and locations
01-11
Repair Manual,
Brake System,
Repair Group 45
3 - ABS/EDL and
ABS/EDL/ASR
hydraulic unit
-N55-
Located on
left of engine
compartment.
The ABS
hydraulic
pump -V64and the
inlet/outlet
valves in the
hydraulic unit
are checked
by On Board
Diagnostic
(OBD)
The ABS
hydraulic
pump -V64and valve
block must
not be
separated
from one
another
Removing
and installing
When
changing the
hydraulic
unit, always
seal the old
part with the
plugs from
the repair set
Part No. 1H0
698 311 A
Стр. 3 из 14Electrical/electronic components and locations
01-12
4 - ABS/EDL and
ABS/EDL/ASR
Control
Module -J104-
Location: on
hydraulic unit
on left of
engine
compartment
Checked by
On Board
Diagnostic
(OBD)
Checking the
multi-pin
connector to
control
module
Page 01-106
Do not
disconnect
connector
before
successfully
completing
OBD. Switch
ignition off
before
separating
connection.
Стр. 4 из 14Electrical/electronic components and locations
01-13
5 - Brake light
switch -F-
The brake
light switch is
open in the
rest position;
Adjusting
Page 01-131
Can be
checked via
read
measured
value block
Page 01
-
61
6 - Data Link
Connector
(DLC)
Installation
position: in
center
console
below
heating/air
conditioning
controls
7 - Longitudinal
acceleration
sensor -G251-
All-wheel
drive
vehicles with
Haldex
coupling only
Стр. 5 из 14Electrical/electronic components and locations
01-14
8 - ABS warning
light -K47-
Location:
instrument
cluster
Function:
Page 01-17
9 - Warning light
for brake
system -K118-
Location:
instrument
cluster
Function:
Page 01-17
10 - ESP control
lamp -K155-
Location:
instrument
cluster
Стр. 6 из 14Electrical/electronic components and locations
01-15
11 - Right/left
front ABS
wheel speed
sensor -G45-/G47-
Checked by
On Board
Diagnostic
(OBD)
Before
inserting the
sensor clean
the inner
surface of
the sensor
mounting
and coat with
lubricating
paste G 000
650
When
connecting
the speed
sensor wire
ensure it is
not twisted in
the wheel
housing
Bolt
tightening
torque - 10
Nm
12 - Wheel hub
with impulse
rotor for
right/left front
speed
sensors
Rotor and
speed
sensors for
front left and
right-hand
sides are
identical
Стр. 7 из 14Electrical/electronic components and locations
Repair Manual,
Suspension, Wheels,
Steering, Repair
Group 40
Removing
and installing
Стр. 8 из 14Electrical/electronic components and locations
01-16
13 - Right/left rear
ABS wheel
speed sensor
-G44-/-G46-
Checked by
On Board
Diagnostic
(OBD)
Before
inserting the
sensor clean
the inner
surface of
the sensor
mounting
and coat with
lubricating
paste G 000
650
When
connecting
the speed
sensor wire
ensure it is
not twisted in
the wheel
housing
Bolt
tightening
torque - 10
Nm
14 - Wheel hub
with impulse
rotor for
right/left rear
speed
sensors
Rotor and
speed
sensors for
left and righthand sides
are identical
Removing
and installing
Стр. 9 из 14Electrical/electronic components and locations
Repair Manual,
Suspension, Wheels,
Steering, Repair
Group 42
Стр. 10 из 14Electrical/electronic components and locations
01-17
Diagnostic Trouble Codes (DTC)
displayed by warning lights -K14-, K47- and -K118-
Warning lights
For vehicles with ABS/EDL/ASR and/or a
radio/navigation system, the warning
light for brake system -K118- is at
position -3-.
The function of the parking brake
warning light -K14- is then taken on by
the warning light for brake system K118-.
Item
Designation
1 Warning light for brake system -
K118-
2 ABS warning light -K47-
3 Parking brake indicator light -K14-
Стр. 11 из 14Electrical/electronic components and locations
01-18
ABS warning light -K47-
Electrical Wiring Diagrams,
Troubleshooting & Component Locations
binder
If the ABS warning light -K47- (-2-) does
not go out after switching ignition on and
completion of test sequence then the
malfunction may be:
-a- Voltage supply is below 10 Volts
-b- There is a malfunction in the ABS
The anti-locking brake system remains
switched off with an ABS malfunction -b-,
but the brake system remains fully
operational.
-c- Since the last time the vehicle was
started there was a temporary speed
sensor malfunction.
In the case of a sensor malfunction -c-,
the ABS warning light -K47- will
extinguish after restarting the engine and
attaining a speed of above 20 km/h
(approx. 13 mph).
-d- The connection from instrument cluster
to ABS control module (w/EDL) -J104- is
interrupted.
-e- Instrument cluster is faulty.
Стр. 12 из 14Electrical/electronic components and locations
01-19
ABS warning lights -K47- and -K118-
Electrical Wiring Diagrams,
Troubleshooting & Component Locations
binder
WARNING!
After the ABS warning light -K47- and
warning light for brake system -K118have illuminated it is possible that the
rear wheels will lock-up earlier when
braking.
If the ABS warning light -K47- (-2-) goes
out but the warning light for brake
system -K118- (-1-) remains on and
three warning tones are audible then the
malfunction may be:
-a- The brake fluid level is too low.
-b- There is a malfunction in the activation
of the warning light for brake system K118-.
If the ABS warning light -K47- (-2-) and
the brake system warning light -K118- (1-) light up, the ABS system is faulty
and the EBD (Electronic Brake pressure
Distribution) is not functioning.
Стр. 13 из 14Electrical/electronic components and locations
01-20
Parking brake indicator light -K14-
Electrical Wiring Diagrams,
Troubleshooting & Component Locations
binder
Vehicles with ABS/EDL
Malfunction: Vehicle has no EDL
function
For this complaint a possible cause may be
the brake light switch -F- is incorrectly
adjusted. Adjusting brake light switch
Page 01-131 .
Another possible cause may be the brake
light switch -F- is not functioning. The
function can be checked in Read measured
value block Page 01
-61 , display group
number 003.
If the parking brake indicator light -K14-
-3- does not go out after switching the
ignition on, the malfunction may be:
-a- The parking brake is applied.
-b- The parking brake warning light switch F9- for the parking brake indicator light K14- is faulty or incorrectly adjusted.
-c- There is a wire routing malfunction.
Стр. 14 из 14Electrical/electronic components and locations
01-21
ABS ITT Mk 20 IE On Board
Diagnostic (OBD) program
All functions which could previously be
performed with V.A.G 1551 can also be
performed with the new tester VAS 5051.
Special tools and equipment
V.A.G 1551 Scan Tool or V.A.G 1552
vehicle system tester.
V.A.G 1551/3 or 1551/3A Adapter cable
Стр. 1 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-22
Test requirements
The tires installed to all wheels must be of
the same (approved) size; tires inflated to
prescribed pressure.
Mechanical/hydraulic parts of the brake
system including brake light switch and
brake lights OK.
Hydraulic lines and connections not leaking
(visual check of hydraulic unit, brake
calipers, wheel cylinders, tandem master
brake cylinder).
Wheel bearings and wheel bearing play
OK.
ABS control module (w/EDL) -J104- is
correctly bolted to hydraulic unit -N55-.
Connector on ABS control module (w/EDL)
-J104- correctly plugged-in (retainer is
engaged).
Check contacts of ABS components for
damage and correct seating.
All fuses OK according to wiring diagram
(remove fuse from fuse holder to check).
Supply voltage OK (at least 10.0 V).
Стр. 2 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-23
V.A.G 1551 Scan Tool, connecting and
selecting function
Note:
All functions which could previously be
performed with V.A.G 1551 can also be
performed with the new tester VAS 5051.
The ABS function is switched off in the control
module during the On Board Diagnostic (OBD)
.
The Diagnostic Trouble Code (DTC) memory
can be erased after successful checking and
repair.
Connecting VAS 5051 Page 01-31 .
- Pull cover -1- off in direction of arrow.
- With ignition switched off connect V.A.G 1551
using cable V.A.G 1551/3(A) to Data Link
Connector
V
.A.G - On Board Diagnostic HELP
1 - Rapid data transfer1
)
2 - Blink code output1
)
Indicated on display
1)
Is displayed alternately
Note:
If there is no indication on display, check DLC,
Electrical checks Page 01-102 , test steps 14
and 15.
Depending on the program, additional operatin
g
information can be printed out by pressing the
HELP key of V.A.G 1551.
The key is used for moving forward within
the program.
Стр. 3 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-24
The PRINT key is used for switching on the
printer (warning lamp in key comes on).
- Switch ignition on.
- Switch on printer with Print key (indicator lamp in
key lights up).
- Press key -1- for "Rapid data transfer" operating
mode.
Rapid data transfer HELP
Enter address word XX
Indicated on display
- Press keys -0- and -3-; 03 inputs the address
word of the vehicle system to be tested "Brake
electronics".
Rapid data transfer Q
03 - Brake electronics
Indicated on display
- Confirm input with Q key.
1J0 907 379 D ABS 20 IE CAN 0001
Coding 03604 WSC XXXXX
Display shows e.g.
Displayed is:
e.g. (1J0 907 379 D)
Allocation of control module see Parts catalog
Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder
The control module identification number.
System designation (ABS 20 IE)
Data BUS present. (CAN)
Стр. 4 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-25
Control module code (03604).
Coding control module Page 01-58
Workshop code
V.A.G 1551 Scan Tool operating
instructions
If the control module identification number
does not appear Summary of selectable
functions Page 01
-27
-
Press key.
Rapid data transfer HELP
Select function XX
Indicated on display (select function, e.g. 02
- Check DTC memory).
Rapid data transfer HELP
Control module does not answer!
Indicated on display
By pressing the HELP key, a list of possible
fault causes is printed out.
If "Control module does not answer!" again
appears:
- After eliminating possible causes of
malfunctions, enter the address word 03
for "Brake electronics" again and
confirm.
Rapid data transfer HELP
Control module does not answer!
Indicated on display
- Perform test steps 1, 2 and 3 Page
01-102 , Electrical check.
Rapid data transfer
No signal from control module!
malfunctions have occurred during checking
of control module identification (possibly
influenced from external sources?)
Стр. 5 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-26
- Check DLC as well as voltage supply and
Ground connection for ABS Control Module
(w/EDL) -J104-, Electrical check, Page 01-
102 .
- After repairing possible causes of malfunction,
again enter address word 03 for "Brake
electronics" and confirm with Q key.
Стр. 6 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
01-27
List of selectable functions
Page
00
-
Automatic test sequence Page
01-30
01
-
Check control module version
Connecting V.A.G 1551 Scan
Tool and selecting functions
Page
01-23
02
-
Check DTC memory Page
01-28
03
-
Output Diagnostic Test Mode Page
01-74
04
-
Initiate basic setting Page
01-91
05
-
Erase DTC memory Page
01-56
06
-
End output Page
01-56
07
-
Code control module Page
01-58
08
-
Read measured value block Page
01-61
Стр. 7 из 81ABS ITT Mk 20 IE On Board Diagnostic (OBD) program
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