Emissions Recall WA - Reprogramming Of Engine Control Module And Replacement Of Malfunctioning Oxygen Sensor (WA/WA00)

WARNING: This page is about the Jetta GLS, 1.8 D, AWD, Automatic, which is a different variant/trim than selected.

Publication date: 2007-05-01
Reference number: WA/WA00

EMISSIONS RECALL WA - REPROGRAMMING OF ENGINE CONTROL MODULE AND REPLACEMENT OF MALFUNCTIONING OXYGEN SENSOR

SERVICE CAMPAIGN BULLETIN

Reference Number(s): WA/WA00 Revised, Date of Issue: May 2007

VOLKSWAGEN:

1999-2001 Golf/ Jetta and New Beetle

IMPORTANT: Please inform and provide a copy of this document to every person in your dealership with campaign-related responsibilities, including Service, Parts and Accounting personnel. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety. If you have questions regarding this or any other campaign, please call (800) 741-2919.

SUBJECT

1999-2001 Volkswagen Golf/ Jetta and New Beetle 2.0 Liter Gasoline Engine Vehicles

Reprogramming of Engine Control Module and Replacement of Malfunctioning Oxygen Sensor

Revision Summary

Work procedure includes updated instructions for ECM reprogramming.
New WA ECM Update programming CD ROM shipped to dealers.
Control Module Tuning Form attached.

PROBLEM DESCRIPTION

Volkswagen has found that the oxygen sensor in the upper part of the exhaust system could fail under certain conditions, potentially causing a vehicle to exceed Federal and/or California emission standards, or to experience increased fuel consumption. "Thermal shock" within the sensor caused by moisture accumulation could cause oxygen sensor failure. If the oxygen sensor fails, the vehicle's "check engine" light on the dashboard will illuminate.

CORRECTIVE ACTION

Check the emission control system for proper function, reset electronically the engine's control module and replace the oxygen sensor, if necessary.

VIN RANGES OF AFFECTED VEHICLES

U.S.A.

1999-2001 Golf

_ _W_ _ _1J_X*343901 - _ _W_ _ _1J_1*005222
(* manufactured in Germany or Brazil)

1999-2001 Jetta

3VW_ _ _9M_XM001756 - 3VW_ _ _9M_1M038741

1999-2001 New Beetle

3VW_ _ _1C_XM408853 - 3VW_ _ _1C_1M417441

CANADA

1999-2001 Golf

_ _W_ _ _1J_X*343901 - _ _W_ _ _1J_1*005222
(* manufactured in Germany or Brazil)

1999-2001 Jetta

3VW_ _ _9M_XM001756 - 3VW_ _ _9M_1M038741

1999-2001 New Beetle

3VW_ _ _1C_XM408853 - 3VW_ _ _1C_1M417441

NOTE: Check ELSAWeb on the day of repair to verify vehicle eligibility and attach the screen print to the repair order. This is the only valid campaign inquiry and verification source. Some vehicles may be involved in an additional action(s); any additional work can be done while the vehicle is in for this action.

NOTE: The allocation report contains owner names and addresses obtained from Motor Vehicle Registration Records. By law, this data may only be used for recall purposes. Use for any other reason may be a violation of law in many states/provinces. Accordingly, you must limit the use of this report.

PARTS INFORMATION

In some instances, this action may require replacement of the front oxygen sensor, part number 06A 906 262Q. Please ensure a minimum supply available to accommodate repair work, if needed.

OWNER NOTIFICATION MAILING

Volkswagen notified all owners of affected vehicles on or about December 27, 2001. A copy of the owner letter is enclosed for your information.

REQUIREMENTS FOR EMISSIONS CAMPAIGNS HAVING CUSTOMER NOTIFICATION (CALIFORNIA ONLY)

The California Air Resources Board and the Department of Motor Vehicles (DMV) require emissions-related campaigns to be completed prior to vehicle registration renewal. When campaign work is done you must provide the owner with a signed "Vehicle Emission Recall - Proof of Correction" certificate (RC EMIS_CAL VW) which can be ordered from Resolve at 1-800-544-8021.

NOTE: Ensure owners are aware of the importance of retaining the completed certificate for their records. It should be mailed to the California DMV only upon request.

EMISSIONS CAMPAIGN VEHICLE LABELING GUIDELINES (CALIFORNIA ONLY)

Vehicles repaired under emission campaigns in the state of California are required by the California Air Resources Board (CARB) to be identified with an emission campaign completion label when the work is performed. It is mandatory for all dealers in the state of California to complete and affix an emission campaign completion label (part number ZVW 010 000) whenever an emissions campaign is performed. Labels can be ordered from Resolve at 1-800-544-8021.

CLAIM ENTRY PROCEDURE

Immediately upon completion of the repair work, enter the correct code listed below. Claims will only be paid for vehicles that show this campaign open in ElsaWeb on the day of the repair. To help ensure prompt and proper payment, attach the screen print to the repair order.

CLAIM ENTRY PROCEDURE

Damage Code	Time Units	Work Scope
WA 11	25 T.U.	- Check - NO reprogram of ECM necessary
WA 12	70 T.U.	- Reprogram ECM only
WA 13	120 T.U.	- Reprogram ECM and replace oxygen sensor
WA 13	120 T.U.	1	06A 906 262Q	Oxygen sensor
WA 20	0 T.U.	- Customer refused repairs
There is NO reimbursement for Vehicle Wash or Loaner Vehicle. The system will enter part and labor applicable to the codes above.

Fig 1: WA Saga Claim Entry Procedure

CUSTOMER LETTER EXAMPLE (U.S.A.)

December 2001

Subject: Recall WA: Reprogramming of Engine Control Module and Replacement of Malfunctioning Oxygen Sensor

Dear Volkswagen Owner:

We are writing to inform you of a potential problem within the emission control system on some 1999 through 2001 model Volkswagen Jetta, Golf and New Beetle 2.0 liter gasoline vehicles. Our records show that you are the owner of one of these vehicles.

What Is The Problem?

Your vehicle is equipped with an oxygen sensor in the exhaust system that provides information to the engine control module. The information the sensor provides is needed to control the fuel and air mixture in the engine at precise levels. Volkswagen of America, Inc. and the Environmental Protection Agency have found that this oxygen sensor could fail under certain conditions, potentially causing your vehicle to exceed emission standards, or to experience increased fuel consumption.

The oxygen sensor failure could be caused by "thermal shock" within the sensor caused by moisture accumulation.

Your vehicle is equipped with an onboard diagnostic system (OBD) which will warn you if certain emission-related failures occur in your car. The oxygen sensor is part of this system as well, and needs to operate correctly to allow the OBD system to do its job. If the oxygen sensor fails, the "check engine" light on your vehicle's dashboard will illuminate. If your vehicle has a "check engine" light on, contact your authorized Volkswagen dealer as soon as possible, to arrange an appointment. However, do not wait for the light to come on before seeking service under this recall notice because the free service provided under this recall will prevent the type of oxygen sensor failure described above.

What Will Volkswagen Do?

Your authorized Volkswagen dealer will check your vehicle's emission control system for proper function, reset electronically the engine's control module and replace the oxygen sensor, if necessary.

What We Would Like You To Do

Please contact the Service Department of any authorized Volkswagen dealer and schedule an appointment as soon as possible. Please present the enclosed "Campaign Authorization" form, which identifies your vehicle to your dealer, when you bring your Volkswagen for this service. The necessary work will take approximately one hour and will, of course, be free of charge.

Please note that this work will be performed free of charge by authorized Volkswagen dealers only. Volkswagen will not pay for any such work performed by non-authorized Volkswagen facilities. Volkswagen will neither reimburse owners for such work, unless it is performed by an authorized Volkswagen dealer, nor will Volkswagen reimburse any service facility which is not authorized by Volkswagen to perform such work.

California Regulations (FOR CALIFORNIA VEHICLES OWNERS ONLY)

California regulations require that this repair be completed prior to the time that you renew your vehicle registration. Please make sure that this repair is completed prior to the renewal of your vehicle registration and that you furnish proof of repair to the DMV in the form of a copy of the dealer's repair order including a signed "Emission Campaign Performance Authorization" which is enclosed with this letter. Please retain the signed certification form with your vehicle records. DO NOT MAIL THIS FORM to the Department of Motor Vehicles (DMV), unless requested.

If you are the lessor and registered owner of the vehicle identified in this action, please forward this information immediately by first class mail to the lessee.

Precautions

If the "check engine" light on your instrument panel comes on prior to the completion of this service, please contact your Volkswagen dealer immediately for scheduling the necessary repair.

Reimbursement of Expenses

Please write to us at the address below, if you have incurred out of pocket expenses for replacement of the oxygen sensor, and we would be pleased to review your request for possible reimbursement. Please include any receipts you have.

Volkswagen of America, Inc.
Attn: Customer Relations - Hills East (WA)
3499 West Hamlin Road
Rochester Hills, MI 48309
1-800-893-5298

We regret any inconvenience this matter may cause; however, we want to make sure that your vehicle complies with applicable emission requirements and performs to your satisfaction.

Thank you for driving a Volkswagen.

CUSTOMER LETTER EXAMPLE (CANADA)

December 2001

Subject: Recall WA: Reprogramming of Engine Control Module and Replacement of Malfunctioning Oxygen Sensor

Dear Volkswagen Owner:

What Is The Problem?

Your vehicle is equipped with an oxygen sensor in the exhaust system that provides information to the engine control module. The information the sensor provides is needed to control the fuel and air mixture in the engine at precise levels. Volkswagen Canada Inc. has found that this oxygen sensor could fail under certain conditions, potentially causing your vehicle to exceed emission standards, or to experience increased fuel consumption.

The oxygen sensor failure could be caused by "thermal shock" within the sensor caused by moisture accumulation.

What Will Volkswagen Do?

Your authorized Volkswagen dealer will check your vehicle's emission control system for proper function, reset electronically the engine's control module and replace the oxygen sensor, if necessary.

What We Would Like You To Do

If you are the lessor and registered owner of the vehicle identified in this action, please forward this information immediately by first class mail to the lessee.

Precautions

If the "check engine" light on your instrument panel comes on prior to the completion of this service, please contact your Volkswagen dealer immediately for scheduling the necessary repair.

Reimbursement of Expenses

Volkswagen Customer Relations (WA)
P. O. Box 842 STN A
Windsor ON N9A 9Z9
1-800-893-5298

We regret any inconvenience this matter may cause; however, we want to make sure that your vehicle complies with applicable emission requirements and performs to your satisfaction.

Thank you for driving a Volkswagen.

CAMPAIGN WORK PROCEDURE - WA EMISSIONS RECALL

If there are questions regarding the work procedure, contact the Campaign Helpline at 1-800-741-2919.

Read this work procedure completely before doing any work. This procedure describes re-programming the engine control module (ECM) and, if necessary, replacing the front oxygen sensor. Some affected vehicles, however, may not require re-programming of the ECM, which will be made apparent during the checking process. This new procedure does not require use of the VAS 6103 serial port cable.

SPECIAL TOOLS AND EQUIPMENT

PSC 550S or INC 940 Battery charger
VAS 5052 Diagnostic Tester is recommended.
TIP: VAS 5051B Diagnostic Tester can also be used; however, on occasions it may not start the update programming process after update programming has been selected.
3337 Tool
VAG 1788/10 Engine speed adjuster

Fig 2: Special Tools and Equipment

CD ROM containing reprogramming
NOTE: DO NOT DUPLICATE CD A copied CD may not perform the reflash update properly.

Fig 3: WA Action CD ROM

WORK SEQUENCE

NOTE: When performing the update programming procedure, ALL DTCs for all control units are erased. Always first address stored DTCs for customer concerns unrelated to the flash procedure

NOTE: The following "Update - Programming" process may overwrite any "TUNED" ECM programming. The dealership should advise owner accordingly and get owner's written consent to perform the update procedure.

Fig 4: Control Module Tuning Form

NOTE: Battery MUST have a minimum no load charge between 12.5V and 14.5V (failure to maintain voltage during update process can lead to control module failure).

VAS 5051B must be connected to vehicle and 110V AC power supply at all times during update programming.

VAS 5052 must be connected to vehicle and battery voltage requirements maintained.

Any appliances with high electro-magnetic radiation (e.g. mobile phones) switched OFF.

NOTE: Use PSC 550S or INC 940 battery charger to maintain vehicle battery voltage.

SECTION A - ECM DTC Interrogation

Connect diagnostic tester to vehicle data link connector -arrow- using standard diagnostic tester cable. (Fig 5)

Fig 5: Vehicle Data Link Connector

Turn ignition switch to "ON" position.
On diagnostic tester start-up screen, press "Vehicle Self-Diagnosis" button. (Fig 6)

Fig 6: Diagnostic Tester Start-Up Screen

Select Onboard Diagnostics (OBD).
Select "01 - Engine electronics".
Select "004 - DTC Memory content" and check for DTCs.
If DTC is present for the front oxygen sensor, print DTC information, turn ignition switch to "OFF" position, disconnect diagnostic tester from vehicle and proceed to SECTION B.
TIP: DTC print-out must remain with dealership's repair order copy!
If no front oxygen sensor DTC is present, go to SECTION C.

SECTION B - Front Oxygen Sensor Replacement

Disconnect wire harness connector from oxygen sensor.
Use special tool 3337 to remove front oxygen sensor -1- from exhaust manifold. (Fig 7)

Fig 7: Front Oxygen Sensor On Exhaust Manifold

NOTE: Coat threads of new oxygen sensor, 06A 906 262Q, using anti-seize compound marked "safe for oxygen sensors". Do not allow compound to enter slots on sensor body.
Install new oxygen sensor (06A 906 262Q) and tighten to 50 Nm (37 ft. lbs.).
Reconnect oxygen sensor to wire harness; proceed to SECTION C.

SECTION C - ECM Reprogramming

Connect a Volkswagen approved battery charger to vehicle and check battery voltage to ensure it is greater than 12.5 V and less than 14.5 V.
If oxygen sensor was replaced, reconnect diagnostic tester to vehicle and switch ignition to "ON" position.
Insert CD ROM, (WAAACTION0407) into diagnostic tester as soon as the start screen is displayed.
NOTE: Nonobservance of the following points may lead to ECM failure!
VAS 5052 or 5051B must always be connected to the approved power supply at approved voltages. Under no circumstances should the power supply be interrupted or the diagnostic connector unplugged during the flash procedure.

Any appliances with high electro-magnetic radiation (i.e. mobile phones) must be switched OFF.

TIP: You must return to the start screen before starting a new update programming session, otherwise the update programming CD will not be recognized by the diagnostic tester.

Fig 8: Diagnostic Tester Start-Up Screen

If VAS 5052/5051B was disconnected, reconnect it to vehicle data link connector using standard diagnostic tester cable.
On diagnostic tester start-up screen, press "Vehicle Self-Diagnosis" button.
Select Onboard Diagnostics (OBD).
Select "01 - Engine electronics".
Select "19 - Update programming". (Fig 9)

Fig 9: VAS Display - Select 19 - Update Programming

This screen is displayed; switch ignition "OFF" and ON". (Fig 10)

Fig 10: VAS Display - Update Programming

Read information displayed on WARNING! screen and press the forward arrow button. (Fig 11)

Fig 11: VAS Display - Warning Message

TIP: When using a VAS 5051B, if this WARNING! screen is not displayed and a different screen showing message "The EDIABAS does not deliver a system error" is displayed, press "Canceling" button and another screen instructing to turn ignition switch "OFF" and "ON" will be displayed. Press "Ignore" button and tester will return to "01 - Engine Electronics." Disconnect VAS 5051B from vehicle and connect VAS 5052. If there is no access to ECM, exit program, start vehicle and run for a few seconds and shut off. ECM access should be available.

If update programming cannot be started, please call 1 (800) 741-2919 and ask for technical assistance.

Programming progress screen is displayed and update programming begins. (Fig 12)

Fig 12: VAS Display - Programming Progress

Tip: This illustration (Fig 13) and the following two illustrations are steps to do if the update programming stops before 100% completion.

Fig 13: VAS Display - Control Module Does Not Answer

If at any time during the update programming this screen appears press the "Canceling" button. (Fig 13)
After pressing the "Canceling" button this screen is displayed. (Fig 14) Press "Ignore" button and tester will return to control module selection screen. DO NOT switch ignition "OFF" and "ON" or control unit will be destroyed.

Fig 14: VAS Display - Press "Ignore" Button

NOTE: Once the update programming process has been initiated, the ignition switch must not be turned "OFF" until the update programming reaches 100% or the control unit will be destroyed.
Select "01 - Engine electronics".
Select "19 - Update programming". (Fig 15)

Fig 15: VAS Display - Select 19 - Update Programming

Press the forward arrow button and update programming progression screen will be displayed and update programming will be restarted.
After update programming is 100% complete, switch ignition "OFF" and "ON". (Fig 16)

Fig 16: VAS Display - Update Programming

Screen displays previous control unit part number -arrow 1- and new control unit part number -arrow 2-. (Fig 17)

Fig 17: VAS Display - Control Unit Part Numbers

Make a screen print and attach to work order.
Press forward arrow button.

TIP: If update programming stopped and needed to be restarted, this screen may not be displayed. Another screen showing a message "The EDIABAS does not deliver a system error" can be displayed. Press the "Canceling" button and another screen instructing to turn ignition switch "OFF" and "ON" will be displayed. Press "Ignore" button and tester will return to "01 - Engine electronics" showing new ECM part number and software level. Erase DTCs in ECM and go to Section D.

Switch ignition "OFF" and "ON". (Fig 18)

Fig 18: VAS Display - Switch Ignition "OFF" and "ON"

Press the back arrow button. (Fig 19)

Fig 19: VAS Display - Erase DTC Memory

Erase DTCs in ECM; proceed to SECTION D.

Section D - Code Control Module

NOTE: Although a code may be shown in the upper right hand corner of screen, the control unit still must be coded.

Select "016 - Access authorization" and press forward arrow button.
Press buttons -1-, -2-, -8- and -3- to input login code 1283.
Press -Q- button to confirm.
Press return arrow button two times when "Function Performed Successfully" comes on in upper left corner of screen.
Select "009 -Coding" and press forward arrow button.
NOTE: Although a code is shown in the upper right hand corner of screen, the control unit still must be coded.

Enter relevant code number for vehicle noting model year and options.

ENGINE CONTROL MODULE CODING, MY 1999

Transmission	ABS	Coding
Manual	Yes	00000
Automatic	Yes	00001
Manual	No	00040
Automatic	No	00041

ENGINE CONTROL MODULE CODING, MY 2000

Transmission	ABS	Air Bag	Coding
Manual	No	No	00001
Manual	Yes	No	00011
Manual	No	Yes	00021
Manual	Yes	Yes	00031
Automatic	No	No	00003
Automatic	Yes	No	00013
Automatic	No	Yes	00023
Automatic	Yes	Yes	00033

Press -Q- button to confirm input.

TIP: Message "Function is unknown or cannot be carried out" is displayed if an unauthorized code number has been entered.

TIP : ECM identification and coding are displayed in upper right corner of screen.

Press return arrow button twice when "Coding of vehicle completed" appears on screen in upper left corner; proceed to Section E.

SECTION E - Create Engine Readiness Code

Requirements for Generating Engine Readiness Code:

Vehicle in stationary position
Automatic transmission selector lever in P (Park) or N (Neutral) position
Turn off all electrical consumers (e.g. lights and rear window defroster)
Throttle valve angle less than 10% - See Display Group 3, display field 3
Coolant temperature at least 85°C - See Display Group 4, display field 3
Intake air temperature less than 60°C - See Display Group 4, Display Field 4

Select "006 - Basic setting" and press forward arrow button.
Press buttons -9- & -8- for Display Group 98: Throttle Body Adaptation.
Press "Q" button to confirm.
Press return arrow button when "ADP. O.K." is on screen.
Start engine and let idle.
Press buttons -7- & -7- for Display Group 77: Secondary Air Check.
Press "Q" button to confirm.

TIP: Test may not start until temperature (on screen) reaches approx. 76.5°C.

Press return arrow button when "Syst. OK" is on screen.
Press buttons -7- & -0- for Display Group 70: EVAP System.
Press "Q" button to confirm.

TIP: Test may not start until temperature (on screen) reaches approx. 76.5°C

Press return arrow button when "TBV OK" is on screen.
Press buttons -7- & -1- for Display Group 71: Leak Test EVAP System.
Press "Q" button to confirm.
Press return arrow button when Syst. OK is on screen.
Press buttons -3- & -4- for Display Group 34: Oxygen Sensor Aging.
Press "Q" button to confirm.
Using VAG 1788/10 set engine speed to 2200 - 2800 RPM.

TIP: Test may not start until temperature (on screen) is higher than 352.0°C.

Press return arrow button when B1-P1. OK is on screen.
Press buttons -4- & -6- for Display Group 46: Catalytic Converter.
Press "Q" button to confirm.
Using VAG 1788/10 set engine speed to 2800 - 3200 RPM.

TIP: Test may not start until temperature (on screen) is higher than 352.0°C.

Press return arrow button when Cat "B1 OK" is on screen.
Remove VAG 1788/10 from vehicle to bring engine down to idle.
Press return arrow button two times.
Select "020 - Special functions" and press forward arrow button.
Select "020.01 Readiness code" and press forward arrow button.
Readiness code should read 00000000 test complete.
Press "Print" button for copy to attach to repair order.
Press return arrow button.
If vehicle has automatic transmission, turn ignition switch to "OFF" position, press return arrow button two times and proceed to Section F; otherwise, go to next step.
Select "022 - End Output".
Switch ignition to "OFF" position
NOTE: The coding values entered and shown on display will not be used by the Motronic Control Module UNTIL the ignition has been switched OFF once.
Disconnect VAS 5052 / 5051B diagnostic cable harness from data link connector.

Section F - Automatic Transmission - Initiating Basic Settings

Turn ignition switch to "ON" position.
Select "02 - Gearbox Electronics" and press forward arrow button.
Select "006 - Basic Settings" and press forward arrow button.
Press -0- button for Display Group 0: Basic Setting.
Press "Q" button to confirm.
Depress accelerator pedal as far as kick down and hold in this position for 3 seconds.
Press return arrow button.
Select "022 - End output".
Release accelerator pedal.
Print diagnosis log showing readiness has been completed and attach to R.O.
Switch ignition to "OFF" position.
NOTE: The coding values entered and shown on display will not be used by the Motronic Control Module UNTIL the ignition has been switched OFF once.
Disconnect VAS 5052 / 5051B diagnostic cable harness from data link connector.
Destroy and properly dispose of any removed parts.

WORK IS COMPLETE.