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3/16/2019 Technical Service Bulletin 2018652/6

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Copyright VW AG

Technical Service Handbook (HST) ElsaPro Job no.: 63988DMS Repair Order number: undefined VIN: WVWJK73CX9P049479 Model year: 2009Model code: 3C25L6 Model description: Passat Sed. NAR 147 A6FEngine code: CCTA Transmission code: KGULicense plate: Final drive code:User name: GARCIA Service advisor name: GARCIA, MAURICIO (mgarcia1)

Basic filtering of vehicle descriptionBasic filtering of vehicle description

Brand Model year Model code Eng. Code Trans. Code Final drive code

V 2009 3C% ALL with 2.0L CCTA, C CCTA % %

Technical Service BulletinTechnical Service Bulletin Transaction No.: 2018652/62018652/6

01-17-05 - MIL ON, DTCs P1545, P0121, P0123, P0221 or P0222 Stored in ECM Fault Memory Release date: Mar 9, 2017

ConditionCondition

Model(s)Model(s) YearYear Eng. CodeEng. Code Trans. CodeTrans. Code VIN Range FromVIN Range From VIN Range ToVIN Range To

(A5) Jetta, Rabbit,(A5) Jetta, Rabbit,GTI, Passat, PassatGTI, Passat, Passat

Wagon, EosWagon, Eos2006-20082006-2008

2.0L2.0L

(BPY)(BPY)AllAll AllAll AllAll

AllAll 2008-20092008-20092.0L2.0L

(CCTA, CBFA)(CCTA, CBFA)AllAll AllAll AllAll

01 17 05 01 17 05 March 9, 2017 2018652 2018652 Supersedes T. B. V011612 dated July 19, 2016 to update the part table.

MIL ON, DTCs P1545, P0121, P0123, P0221 or P0222 Stored in ECM Fault MemoryMIL ON, DTCs P1545, P0121, P0123, P0221 or P0222 Stored in ECM Fault Memory

Malfunction indicator lamp in instrument cluster is illuminated.

A number of incident memory entries with regard to the throttle valve are stored in the ECM. In most cases, the entries aresporadic.

DTCDTC DescriptionDescription

P1545P1545 Throttle valve control system malfunctionThrottle valve control system malfunction

P0121P0121 Throttle/Pedal Position Sensor/Switch “A” CircuitThrottle/Pedal Position Sensor/Switch “A” CircuitRange/PerformanceRange/Performance

P0123P0123 Throttle/Pedal Position Sensor/Switch “A” Circuit HighThrottle/Pedal Position Sensor/Switch “A” Circuit High

P0221P0221 Throttle/Pedal Position Sensor/Switch “B” CircuitThrottle/Pedal Position Sensor/Switch “B” CircuitRange/PerformanceRange/Performance

P0222P0222 Throttle/Pedal Position Sensor/Switch “B” Circuit LowThrottle/Pedal Position Sensor/Switch “B” Circuit Low

Technical BackgroundTechnical BackgroundPoor contact resistance at throttle valve control module -GX3GX3-.

Production SolutionProduction SolutionOptimized wiring and contacts.



ServiceServiceWiring Harness and Connector Repairs, General InformationWiring Harness and Connector Repairs, General Information

Tip: Tip:

Observe general notes for repairs of vehicle electrical system, see Repair group 97 Wiring in Elsa.

DO NOT solder repairs on vehicle electrical system.

DO NOT repair crimp connectors. If necessary, over lay a wire parallel to inoperative wire.

After crimping a repair connection, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

Yellow wires are to be used exclusively for wiring harness repairs.

Mark repaired areas using yellow adhesive tape.

Yellow wires and areas in wiring harness wrapped with yellow adhesive tape identify a previously performed repair.

Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.

ProcedureProcedure

• Switch Ignition OFF.

• Disconnect battery ground (GND) cable, see Repair Manual Group 27 in Elsa.

WARNING: WARNING:

The steps above must be completed to ensure safety during repair. Also, observe all country-specific regulations.

Figure 1. Correctly preassembled wires and seals.

• Lengthen wires and preassemble seals according to Figure 1.

• Release lock on new wiring harness end connectorhousing using small flathead screwdriver. Use slotmarked in Figure 2.

• Insert all terminals into housing until they audiblyclick.

• Reinstall lock.



Figure 2. Figure 2. Slot to be used to remove lock.

Figure 3. Figure 3. The single wire seal, slid as far as the stop

• Using an appropriate assembly tool, slide the single wire seal up repair wire until it contacts housing. Continue to slideseal into housing as far as the stop (Figure 3).

Figure 4. Figure 4. Crimp connectors installed on wire ends

• Strip wires 6-7mm using tool VAS 1978/3. Install crimp connectors using crimping pliers (base tool) -VAS 1978/1-2 withhead VAS 1978/1-1 (Figure 4).

• Remove car harness insulation to appropriate length (approximately 24cm).

• Lay new harness beside old harness. Cut original wires to fit new harness.

• Twist wires 3 and 5 and 1, 2, 4 and 6 as they were originally.

• Crimp connections.

• Use shrink tip (VAS 1978/15) with hot air gun 220 V/ 50 Hz (VAS 1978/14) to complete installation of shrink tubes.

Note: Note:

When heat-shrinking crimp connections, care must be taken not to damage any other wiring, plastic components orinsulating material with hot nozzle of heat gun. Always observe operating instructions of heat gun.

• Re-insulate harness with yellow tape.

• Check proper function. If necessary, check DTC memory, erase and/or bring systems into basic setting.



Note: Note:

If faults reoccur after repair, replace main throttle.

WarrantyWarranty

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and Procedures Manual To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and Procedures Manual 1)1)

Model(s)Model(s) Year(s)Year(s) Eng. Code(s)Eng. Code(s) Trans. Code(s)Trans. Code(s) VIN Range FromVIN Range From VIN Range ToVIN Range To

(A5) Jetta, Rabbit,(A5) Jetta, Rabbit,GTI, Passat,GTI, Passat,

Passat Wagon, EosPassat Wagon, Eos2006-20082006-2008

2.0L2.0L

(BPY)(BPY)AllAll AllAll AllAll

AllAll 2008-20092008-20092.0L2.0L

(CCTA, CBFA)(CCTA, CBFA)AllAll AllAll AllAll

Claim Type:Claim Type: Use applicable Claim Type Use applicable Claim Type 1)1)

SAGA CodingSAGA Coding

Service Number:Service Number:DamageDamage

CodeCode

Damage LocationDamage Location

(Depends on Service No.)(Depends on Service No.)

Parts ManufacturerParts Manufacturer

(removed part)(removed part)

97529752 00400040 Use applicable when indicated in ElsaUse applicable when indicated in Elsa(L/R)(L/R) WWO WWO 2) European Manufacture2) European Manufacture

97529752 00400040 Use applicable when indicated in ElsaUse applicable when indicated in Elsa(L/R)(L/R) 3ME 3ME 2) Mexico Manufacture2) Mexico Manufacture

Labor OperationLabor Operation 3) 3) :: 97524199 = 90 TU97524199 = 90 TU

Diagnostic Time Diagnostic Time 4)4)

GFF Time expenditureGFF Time expenditure 01500000 = 20 TU max.01500000 = 20 TU max. YESYES

Road TestRoad Test 01210004 = 10 TU01210004 = 10 TU YESYES

Technical DiagnosisTechnical Diagnosis 01320000 = 00 TU max.01320000 = 00 TU max. NONO

Claim Comment: Input “As per Technical Bulletin 2018652” in comment section of Warranty Claim.Claim Comment: Input “As per Technical Bulletin 2018652” in comment section of Warranty Claim.

1)1) Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only

2)2) Code per warranty vendor code policy. Code per warranty vendor code policy.

3)3) Labor Time Units (TUs) are subject to change with Elsa updates.Labor Time Units (TUs) are subject to change with Elsa updates.

4)4) Documentation required per Warranty Policy & Procedures Manual. Documentation required per Warranty Policy & Procedures Manual.

Required Parts and ToolsRequired Parts and Tools

Note: Note:

Verify correct housing and associated wire set in ETKA with specific VIN.

Part DescriptionPart Description Part No:Part No: QuantityQuantity

Set 1Set 1

HousingHousing 4H0 973 7134H0 973 713 11

1.0 mm wire1.0 mm wire 000 979 150 EA000 979 150 EA 11



.5 mm wire.5 mm wire 000 979 025 EA000 979 025 EA 22

Butt connector (Transparent)Butt connector (Transparent) 000 979 940000 979 940 44

Butt connector (Red)Butt connector (Red) 000 979 941000 979 941 22

Wire seal (Yellow)Wire seal (Yellow) 3C0 972 7413C0 972 741 66

Set 2Set 2

HousingHousing 1J0 973 7131J0 973 713 11

1.0 mm wire1.0 mm wire 000 979 131 EA000 979 131 EA 11

.5 mm wire.5 mm wire 000 979 019 EA000 979 019 EA 22

Butt connector (Transparent)Butt connector (Transparent) 000 979 940000 979 940 44

Butt connector (Red)Butt connector (Red) 000 979 941000 979 941 22

Wire seal (Yellow)Wire seal (Yellow) 3C0 972 7413C0 972 741 66

Tool DescriptionTool Description Tool No:Tool No:

Strip pliersStrip pliers VAS 1978/3VAS 1978/3

Crimp pliersCrimp pliers VAS 1978/1-2 - VAS 1978/1-1VAS 1978/1-2 - VAS 1978/1-1

Hot air gunHot air gun VAS 1978/15VAS 1978/15

Additional InformationAdditional InformationAll part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check withAll part and service references provided in this Technical Bulletin are subject to change and/or removal. Always check withyour Parts Dept. and Repair Manuals for the latest information.your Parts Dept. and Repair Manuals for the latest information.

Document Control Revision TableDocument Control Revision Table

Instance NumberInstance Number Published DatePublished Date Version NumberVersion Number Reason For UpdateReason For Update

2018652/6 3/9/17 V011705 Update parts table.

2018652/1 9/18/08 V010825 Original publication.

© 2017 Volkswagen Group of America, Inc.© 2017 Volkswagen Group of America, Inc. All rights reserved. Information contained in this document is based on the latestinformation available at the time of printing and is subject to the copyright and other intellectual property rights of VolkswagenGroup of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time withoutnotice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means,electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to othersites, without the prior expressed written permission of the publisher.

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