Technical Bulletin
Model(s)
Year
(A5) Jetta,
Rabbit, GTI,
Passat, Passat
Wagon, Eos
2006-2008
All
2008-2009
Eng. Code
Trans. Code
VIN Range From
VIN Range To
All
All
All
All
All
All
2.0L
(BPY)
2.0L
(CCTA, CBFA)
Condition
01 09 04 Feb. 18, 2009 2018652 Supersedes T. B. Group 01 number 08 25 dated Sept. 18, 2008 due to
additional model year and additional engine applicability.
MIL 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 are sporadic.
DTC
Description
P1545 Throttle valve control system malfunction
P0121 Throttle/Pedal Position Sensor/Switch A Circuit Range/Performance
P0123 Throttle/Pedal Position Sensor/Switch A Circuit High
P0221 Throttle/Pedal Position Sensor/Switch B Circuit Range/Performance
P0222 Throttle/Pedal Position Sensor/Switch B Circuit Low
Technical Background
Contact resistance in the ECM wiring throttle valve.
Production Solution
Optimized wiring and contacts.
Page 1 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
Wiring Harness and Connector Repairs, General Information
Tip:
Observe general notes for repairs of vehicle electrical system, see Repair group 97 Wiring in ElsaWeb.
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.
Procedure
Switch Ignition OFF.
Disconnect battery ground (GND) cable, see Repair Manual Group 27 in ElsaWeb.
WARNING:
The steps above must be completed to ensure safety during repair. Also, observe all country-specific
regulations.
Page 2 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 1. Correctly preassembled wires and seals.
Use the applicable repair manual in Elsa in addition to the description below. Check ETKA to determine if you
need set 1 or set 2.
Lengthen wires and preassemble seals according to Figure 1.
Release lock on new wiring harness end
connector housing using small flathead
screwdriver. Use slot marked in Figure 2.
Insert all terminals into housing until they
audibly click.
Reinstall lock.
Figure 2. Slot to be used to remove lock.
Page 3 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
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 slide seal into housing as far as the stop (Figure 3).
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 with head 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:
When heat-shrinking crimp connections, care must be taken not to damage any other wiring, plastic components
or insulating material with hot nozzle of heat gun. Always observe operating instructions of heat gun.
Page 4 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Re-insulate harness with yellow tape.
Check proper function. If necessary, check DTC memory, erase and/or bring systems into basic setting.
Note:
If faults reoccur after repair, replace main throttle.
Warranty
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year(s)
(A5) Jetta,
Rabbit, GTI,
Passat, Passat
Wagon, Eos
2006-2008
All
2008-2009
Eng. Code(s)
Trans. Code(s)
VIN Range
From
All
All
All
All
All
All
2.0L
(BPY)
2.0L
(CCTA, CBFA)
VIN Range To
Use applicable Claim Type 1)
Claim Type:
SAGA Coding
Damage
Damage Location
Parts Manufacturer
Code
(Depends on Service No.)
(removed part)
9713
0040
Use applicable when indicated in
ElsaWeb (L/R)
WWO 2) European Manufacture
9713
0040
Use applicable when indicated in
ElsaWeb (L/R)
3ME 2) Mexico Manufacture
Service Number:
Labor Operation 3) : Check DTCs
97524199 = 110 TU
and Repair engine wiring harness
Diagnostic Time 4)
GFF Time expenditure
01500000 = XX TU max.
NO
Page 5 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Road Test
01210004 = 10 TU
YES
Technical Diagnosis
0132xxxx = XX TU max.
NO
Claim Comment: Input As per Technical Bulletin 2018652 in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Code per warranty vendor code policy.
3)
Labor Time Units (TUs) are subject to change with Elsa updates.
4)
Documentation required per Warranty Policy & Procedures Manual.
Required Parts and Tools
Note:
Verify correct housing and associated wire set in ETKA with specific VIN.
Part Description
Part No:
Quantity
Housing (set 1)
5N1-973-206
Wires set with terminals come only
in set of 5 but with terminals on
both ends (set 1)
000-979-025-D
Housing (set 2)
1J0-973-713
Wires set with terminals come only
in set of 5 but with terminals on
both ends (set 2)
000-979-038-D
Connectors with shrink tube (used
with either set)
111-971-941-A
Wire seals (used with either set)
4B0-972740
Page 6 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Tool Description
Tool No:
Strip pliers
VAS 1978/3
Crimp pliers
VAS 1978/1-2 - VAS 1978/1-1
Hot air gun
VAS 1978/15
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.
Page 7 of 7
2009 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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 other sites, without the prior expressed written permission of the publisher.
