I got the engine bay all back together last night save the hose from the expansion tank to the pipe on the back of the motor and decided to start her up. After a few false starts while fuel pressure came up, she fired right up and idled beautifully.

Nonetheless, the Service light is on, and the CEL illuminated after a second or two of running. Both lights were on prior to dismantling, so no surprise there. I am assuming the CEL is still angry about the old transmission malfunction...

I used the demo version of VOL-FCR to pull the codes from it way back when and was thinking about purchasing it to reset those lights... it's either a $200 software purchase or a $140 trip to the shop to have them do it, and I'd rather have the tool when it's over. My only question is whether there is some other software or device which which will reset both OBDII and drivetrain and service codes? I am willing to spend a bit more, because frankly VOL-FCR doesn't exactly impress, and I guess it's very limited in terms of models it supports...

The service light requires special device to clear it, not to worry.

The CEL is a new one. When you disconnected the battery, that deleted all of the codes. Any autoparts store can read the codes for the engine/tranny/abs, my local O'Reilly gives me a scanner to take to the parking lot, where I can read and clear myself - free!

Your new code does need to be looked into...

Glad to hear that it runs!!!

Klaus
--
There is no present time, just the past and future

Auto parts stores aren't allowed to use or rent code readers in California any more, so unfortunately that option won't work. I have not hooked up the demo of vol-fcr again, but neither of my OBDII tools see the CEL, so I am pretty confident the light is for the transmission and not the engine. I went through that before, when I had one code for ELCD and one for transmission, and my code reader only saw the ELCD code. That issue is fixed and that code has not come back.

I guess I should hook up vol-fcr again and see what it says. That software is a big PITA - largely because it makes me mess up my VAG-COM/VCDS software so it'll see the cable. :grr:

The "symptom" of the light is the same as it's been since I got the car... when I start the car, no CEL. About 5-10 seconds after the car has been running the CEL flicks on. Previously, there was only one code stored for the PnP switch (eg "range sensor fault") but it survived numerous battery disconnects. I'm pretty sure it's burned into some NVRAM and needs to be forcibly cleared at this point.

The good news is that after idling for about 5-6 minutes tonight (with new coolant hose & coolant) and shifting through gears to circulate transmission fluid the SERVICE light went off of its own accord, so now I just have the CEL.

I'll torque down the wheel bearings tomorrow and see if some friendly open-on-Saturday repair shop will reset the code. I doubt it. Those guys have a fortune in their tools and charge for them, especially since the state outlawed parts store code readers. Now the average citizen has no choice. :( Sadly, since I rarely take cars anywhere for service, I don't have a relationship with any of them.

The 'service' light will automatically turn off after 2 minutes of engine running. I 'used' that light to remind me not to make use of the turbo until the light turned off. You either get used to it or take a small piece of black tape and cover it up.

If the CEL is turned on for the PNP, replace the PNP. Easily done. Or, with the engine off, 'row' the shifter about 20-30 times from R to L to clean off the PNP contacts - that might help.

Klaus
--
There is no present time, just the past and future

The entire transmission has been replaced, including the PnP.

My OBDII tool showed possible codes for misfires on all cylinders, which I'm positive was a result of it trying to start with no fuel in the fuel lines. Those codes were not there prior to dismantling, and were there before actually going anywhere. I reset them, and don't expect them to come back.

vol-fcr shows a "EFI-666 fault code in TCM" - and I totally forgot to pull the code from the TCM afterwards. Doh! Will do that shortly.

Car runs and drives great. I took it around town, about five miles. Mostly slow traffic, but a few opportunities to give it some boot. No problems. SERVICE light is out, CEL is still on.

I'll look at the TCM fault code and drive it some more, and see what happens.

VOL-FCR is still showing a fault for the range sensor, the same fault that was present back last year. Either the code is "stuck" and needs to be reset, or the TCM itself is faulty and erroneously shows the code.

In any case, I went ahead and ordered a current version of VOL-FCR. I am partly motivated by an intermittent ABS fault - it seems accelerating rapidly through a turn angers the ABS system and the light illuminates. Shutting the car down and restarting it clears the code, but obviously that isn't a good long-term solution. The demo of VOL-FCR shows a code stored in the ABS control module (but hides it), so when I get the full version and can see the actual code and hopefully that will point me towards the issue.

Regardless, the car runs and drives great, and no new engine control module codes have been set after 50 miles of varied driving. More importantly, the car hasn't failed to go those 50 miles reliably, which is a big step from the shenanigans it was pulling last year. ;)