Instrument Cluster - Exhibits Malfunctions

Group: 90

Number: 01-03

Date: Aug. 15, 2001

Subject:
Instrument Cluster, Malfunctioning

Model(s):
New Golf, New Jetta 1999 --> 2001
New Beetle, Passat 1998 --> 2001

Supersedes T.B. Group 90, Number 01-01 dated June 27, 2001

Also Supersedes T.B. Group 90, Number 01-02 dated Aug. 9, 2001

T.B. 90-01-01 Superseded due to change in Part Numbers and CAUTION for using correct terminals.

T.B. 90-01-02 Superseded due error in T.B supersession number.

Condition

Instrument cluster malfunctioning.

May be caused by poor connection between instrument cluster and wiring harness due to poor wiring to terminal crimping or improper terminal tension.

Service

If an instrument cluster exhibits malfunctions, prior to replacing:

- Inspect for faulty terminals related to the concern and replace using the VAS 1978 Wiring Kit as follows:

Note:
If terminals are contaminated with coolant, See Technical Bulletin Group 97 number 01-01 (New Golf/Jetta) or 01-02 (New Beetle).

WARNING!
Disconnect the battery ground (GND) strap before working on the electrical system.





Parts required:

CAUTION!
Part numbers are for reference only. Always check with your Parts Dept. for the latest parts information.

- Remove instrument cluster (see VESIS Repair Manual, Group 90).

- Remove cluster harness connector covers (blue and green).

Terminals, checking crimp

- Inspect for mis-crimped terminals on each affected wire.

- If any wires are mis-crimped:

- Replace affected terminal using, Part No. 000 979 003 (not in VAS 1978 kit, obtain from parts).

CAUTION!
DO NOT use Part No: 000 979 003A (gold plated terminal which is included in the VAS 1978 kit) for this application. Doing so may cause corrosion due to dissimilar metals.

Terminals, checking tension

Using terminal Part No. 000 979 015:

- Test spring tension of contacts by slowly inserting and removing terminal into each cavity.

If any terminal has low tension (easy to remove and install test terminal):

- Replace affected terminal using Part No. 000 979 003.

- DO NOT replace instrument cluster if concern is resolved with above procedures.

WARNING!
Ensure that there is no person inside the vehicle when connecting battery ground strap.

- Connect battery ground (GND) strap.

- Connect VAS 5051 Diagnostic tool.

- Check all systems for stored DTC's.

- Erase any stored DTC's.

Perform the following as necessary after restoring electric power:

- Set Climatronic, power window, and power seat adaptation per Repair Manual and/or Owner's Manual.

- Set engine basic settings (Electronic Throttle Control Adaptation).

- Set clock.

- Set transmission basic settings.

- Set readiness code.

- Set radio anti-theft code and program radio station presets.

- Verify that condition has been eliminated.