Technical product information 2012305/10

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Copyright VW AG

Technical Service Handbook

ElsaPro transaction number: 147294654

DMS order number:

VIN: WVWZZZ3CZ6E....

Model year: 2006

Sales code: 3C5052

Model description: Passat Wag. Trend 103

Engine code: BMP

Gearbox code: HDV

Number plate:

Final drive code:

Username:

Customer advisor name:

Technical product information

Transaction No.: 2012305/10

Engine has no performance, entries

16485,18000,16618,05522,00257,00564

Release date: 25-Feb-2010

Customer statement / workshop findings

The engine has no performance, the engine warning light is on and the following entries can be logged in
the engine control unit:

18000 P1592 sender for intake manifold pressure implausible ratio

05522 P1592 sender for boost pressure/altitude sender implausible ratio

16485 P0101 air mass meter-G70 implausible signal

00257 P0101 air mass meter -G70 implausible signal

16618 P0234 boost pressure control limit exceeded

00564 P0234 boost pressure control limit exceeded

Technical background
Contact resistance in the engine wiring loom. The contact resistance influences the signal values of
boost pressure sensor G31 and air mass meter G70.

Production change
-

Measure

Check whether the complaint is present. To do this switch on the ignition, select function 01 selfdiagnosis and check in measured value block 10 whether there is a deviation > 50 mbar in display
field 2 and 3.

Display group number 10: Air values

Designation

specified
value

Remark

Actual air mass [mg/H]

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Atmospheric pressure [mbar]

900...1100

Actual air mass [mbar]

900...1150

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Actual air mass = value 2 50 mbar

(only valid if engine off and ignition on)

Pedal value sender [%]

Note: Pressure values depend on the height and weather. The tolerance ranges apply to an attitude of
about 300 m.

If there is an increased deviation, proceed as follows:

1.

Clean the earth points

2.

Fit the wiring loom (part number 1KD 971 658)

1)
Check all earth connections in the engine compartment, specifically the connections in the plenum
chamber and on the side members. Look out particularly for possibly twisted or not fully touching cable
shoes on the cable ends. Detach the affected earth connections and clean the earth pin and the contact
surfaces of the cables with the contact surfaces cleaner VAS 6410 (even if the contact surfaces seem
fine). Reseal the screwed connection with conservation wax (Part No. AKR 321 M15 4).
2)
Remove the engine control unit and take off the plug. Take off the plug on the sender for boost pressure
G31/G42 and tie it back. Dismantle the 94 pin connector housing for the engine control unit, see
attachment, and remove the pins for the boost pressure sender G31 and intake air temperature sender
G42.
See the current flow diagrams for the precise pin assignments of the cables for the G31/G42 in the 94
pin connector housing.
Route the wiring loom along the existing engine wiring loom to the engine control unit. To do this remove
the necessary trim and components in the engine compartment. Slot the pins of the wiring loom in the
clips of the 94 pin connector housing and refit the 4 pin plug on the G31/G42. Assemble in reverse order.

Warranty accounting instructions

Service number/ damage code/ manufacturer: 9713/ 0021/
Accounting with APOS:
Golf 1K*, Golf Plus 5M1, Touran 1T*, Passat 3C*, Eos 1F7
Repair operation
number

Designation

Time units
TU

Main operation

97 52 01 99

Check engine wiring loom

20 TU

Associated
operation

97 26 41 50

Repair contact sensor for wiring

10 TU
loom

Golf 1K*, Golf Plus 5M1, Touran 1T*

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Repair operation
number

Designation

Time units
TU

Main
operation

23 60 19 00

Remove and install EDC control

unit

70 TU

Main
operation

23 60 19 03

Remove and install EDC control

unit

90 TU

Repair operation
number

Designation

Time units
TU

Main
operation

23 60 19 00

Remove and install EDC control

unit

50 TU

Main
operation

23 60 19 03

Remove and install EDC control

unit

70 TU

Passat 3C*, Eos 1F7

Golf 1K*, Golf Plus 5M1, Touran 1T*, Passat 3C*, Eos 1F7

Associated
operation

Repair operation
number

Designation

Time units
TU

97 52 55 99

Replace engine wiring

loom

* TU

Repair operation 97135599 (replace engine wiring loom) includes all work to replace engine the wiring
loom.
Repair operation 97135599 (replace engine wiring loom) is an open time.
Accounting with APOS/2:
Model
1K*,5M1,
1F7, 1T*
1K*,5M1,
1F7, 1T
1K*,5M1,
1F7, 1T

Illustration Position

Number

Activity

Time units (TU)

906-20

P90600

19

971-09

972619

02

20

971-09

972619

56

Repair operation 97261956 (replace engine wiring loom) includes all work to replace engine the wiring
loom.
Repair operation 972619 56 (replace engine wiring loom) is an open time.
1x earth connection in engine compartment

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Model

Illustration Position

Number

Activity

Time units (TU)

1K*

971-00

971250

42

10

40

1x earth connection in engine compartment

Model

Illustration Position

Number

Activity

Time units (TU)

5M1,
1F7

971-01

971250

42

10

40

1x earth connection in engine compartment

Model
1T*
Model

Illustration
972-00
Illustration

Position
40
Position

Number
971250
Number

Activity
42
Activity

Time units (TU)

10
Time units (TU)

3C*

906-20

P90600

19

3C*

971-15

971604

02

20

3C*

971-15

971604

56

Repair operation 97160456 (replace engine wiring loom) includes all work to replace engine the wiring
loom.
Repair operation 971604 56 (replace engine wiring loom) is an open time.
1x earth connection in engine compartment
Model

Illustration Position

Number

Activity

Time units (TU)

3C*

971-65

971250

42

10

50

Repair 1x earth connection in engine compartment - 10TU.

The labour times are correct at the time of publication.
The time units (TU) may differ slightly, if the repair catalogue has been updated.
The information in the repair operations catalogue applies, except for the open time items (... 99).

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