Service Action ZR - Replace Engine Control Module (USA) (ZR (USA))
Publication date: 1996-03-01Reference number: ZR (USA)
SERVICE ACTION ZR - REPLACE ENGINE CONTROL MODULE (USA)
SERVICE CAMPAIGN BULLETIN
| VOLKSWAGEN: | 1996 Golf, Jetta, GTI, Passat and Cabrio |
SUBJECT
1996 Model Volkswagen Golf, Jetta, GTI, Passat and Cabrio Vehicles
Replace Engine Control Module
We wish to inform you of a service action program involving 1996 model Golf, Jetta and GTI 4-cyl, Passat 4 and 6 cyl and Cabrio vehicles. The affected vehicles are within the following vehicle identification number ranges:
Golf, Jetta, GTI (4-cyl)
- 3VW__81H_TM000001 - 3VW___81H_TM053685
Passat (4-cyl)
- WVW___3A_TE000001 - WVW___3A_TE093453
Passat (6-cyl)
- WVW___3A_TE000001 - WVW___3A_TE094401
Cabrio
- WVW___1E_TK000001 - WVW___1E_TK009071
This Service Action affects vehicles according to the following priorities:
- Vehicles in dealer inventory
- Customer vehicles with a complaint
- Vehicles in dealership for maintenance or repair work
PROBLEM DESCRIPTION
It is possible that if an affected vehicle idles for an extended period of time after cold-start in a region with low ambient temperature, the MIL (Malfunction Indicator Light) located in the instrument panel may illuminate because of an overly sensitive ECM (Engine Control Module).
REMEDIAL SERVICE
Replace ECM with latest version control unit.
Please note that some vehicles within the affected VIN range may have been corrected either at port facilities or at the factory. Therefore, it is imperative that you check the V-Crest system for the "open" ZR code prior to commencing work on any of the affected vehicles.
Please ensure that ECM's are being replaced in vehicles in your inventory without delay.
RETAILED VEHICLES
Owners of previously retailed vehicles will not be requested to return their vehicle to their dealer for the update. Instead, these vehicles are to be updated during the next upcoming maintenance or repair service.
PARTS SUPPLY
Based on your vehicle inventory, replacement parts are being automatically shipped to you. Therefore please refrain from ordering parts for your inventory.
We request that you do not deliver a vehicle without first checking/replacing the ECM unless you do not have a replacement ECM immediately available.
The part number for the latest version control units are as follows:
- Golf/Jetta, GTI (4-cyl): 037 906 259 X
- Passat (4-cyl): 037 906 259 C
- Passat (6-cyl): 021 906 259 B
- Cabrio: 037 906 259 B
WORK PROCEDURE
A. CHECK ECM - 1996 GOLF, JETTA, GTI 4-CYL ONLY
- With VAG 1551/1552, check ECM version.
- If ECM shows blue and green dots and VAG 1551 readout showing next to part number is "V08", no further work is necessary.
- Replace ECM with the latest version, identified with a blue and green dot, where necessary, according to step B.
B. REPLACE ENGINE CONTROL MODULE (ECM) ALL MODELS
- Remove ECM.NOTE: Prior to removing ECM, connect VAG 1551; check DTC (Diagnostic Trouble Codes) readout and correct if other than P0125/16509.
- Ignition switch off.
- Remove plenum chamber cover, right side.
- Disconnect 68 pin connector -1-. (Fig 1)
- Remove bolt and nuts -2- and -2a-. (Fig 1)
- Pull out mounting plate -3- with ECM -4-. (Fig 1)
- Separate mounting plate from ECM, removing screw -5-. (Fig 1)
- Do not remove felt pads -6- from mounting plate. (Fig 1)
- Install and Set New ECM.NOTE: When installing the ECM, identification label must be upward.
- Install latest version ECM.
- Ensure that plastic clip - see Fig 1 - is properly in position.
- Tighten bolt and nut -2- and -2a- (10 Nm. - 7 ft lb). (Fig 1)
- Ignition switch on.
- Code Control Module (Scan Tool Function 07). Follow procedure in appropriate repair manual.
- Check DTC Memory (Scan Tool Function 02). Follow procedure in appropriate repair manual.
- Erase DTC Memory (Scan Tool Function 05). Follow procedure in appropriate repair manual.
- Perform Basic Setting
- Press buttons -0- and -4- to select "Basic Setting" Function 04 and press -Q- button to confirm input.
- Press buttons -0-, -9- and -8- to input display 098 and press -Q- to confirm input.NOTE: Do not depress accelerator pedal.
- VAG 1551 display in channel 4 will indicate adaptation completed by showing "I.O."
- Wait at least 30 seconds before ending basic setting then press -> button.
- Press button -0- and -6- and press -Q- button to confirm input - (end output).
- Disconnect VAG 1551.
- Start engine and let idle until coolant temperature is above 80 degrees Centigrade.
- Reconnect VAG 1551.
- Check DTC Memory (Scan Tool Function 02). Follow procedure in appropriate repair manual.
- Set and verify readiness code - 01.29 - 01.54. Follow procedure in appropriate repair manual.
If display does NOT show "I.O.", stop procedure at this step find cause and repair. Begin again with "Basic setting". If "I.O." continue with next step.
PARTS RETURN
All removed engine control modules must be properly tagged/packed and returned in the original shipping box - immediately following the repair - to your facing parts depot.
REPLACEMENT TIME/REIMBURSEMENT
To ensure proper payment, be sure to enter correct reimbursement data into the system only for VIN's showing the ZR code in the V-Crest system.
| Damage Code | Time Units | Work Scope | ||
|---|---|---|---|---|
| ZR 11 | 20 T.U. | Check ECM; Correct unit Shows Blue and Green Identification Dots and V08 Code. NO replacement necessary | ||
| ZR 12 | 80 T.U. | Replace ECM (Inventory vehicle) | ||
| 1 | ECM | 037 906 259 X | ||
| ZR 13 | 80 T.U. | Replace ECM (Customer Owned Vehicle with Complaint or Corrected During Maintenance/Repair Work) | ||
| 1 | ECM | 037 906 259 X | ||
| Wash/Vacuum Vehicle ($7.00) | ||||
| Damage Code | Time Units | Work Scope | ||
|---|---|---|---|---|
| ZR 14 | 100 T.U. | Replace ECM (Inventory vehicle) | ||
| 1 | ECM | 021 906 259 B or 037 906 259 C | ||
| ZR 15 | 100 T.U. | Replace ECM (Customer Owned Vehicle with Complaint or Corrected During Maintenance/Repair Work) | ||
| 1 | ECM | 021 906 259 B or 037 906 259 C | ||
| Wash/Vacuum Vehicle ($7.00) | ||||
| Damage Code | Time Units | Work Scope | ||
|---|---|---|---|---|
| ZR 16 | 100 T.U. | Replace ECM (Inventory vehicle) | ||
| 1 | ECM | 037 906 259 B | ||
| ZR 17 | 100 T.U. | Replace ECM (Customer Owned Vehicle with Complaint or Corrected During Maintenance/Repair Work) | ||
| 1 | ECM | 037 906 259 B | ||
| Wash/Vacuum Vehicle ($7.00) | ||||
The system automatically enters the appropriate labor and part number for the above listed codes.
PROGRAM VERIFICATION
It is important that you check the V-Crest system for the "open" ZR code prior to performing the work. Volkswagen will not reimburse you for duplicate repairs.
OWNER NOTIFICATION
If the owner brings his or her OBD II equipped vehicle to your dealership for maintenance or repair service, kindly explain the importance of the following operating instructions, contained in the owners manual:
- "Do Not Let Your Vehicle Stand and Warm Up
- When the engine is idling, it takes a long time to warm up. Moreover, during warm-up, both engine wear and exhaust emissions are very high. Therefore, be ready to drive off immediately after starting the engine and avoid high speeds."
OWNER SATISFACTION
To aid customer satisfaction as well as minimize inconvenience, you are urged to service a customer-owned vehicle with MIL illuminated at the scheduled appointment time and make sure that the vehicle is returned to the customer washed as well as cleaned inside.
SERVICE HELP
If you have any questions regarding this program, please feel free to contact me at (810) 340-4850 or (810) 340-4858.
DEALER PERSONNEL INFORMATION
Please provide a copy of this communication to every person in your dealership who has campaign-related responsibilities.