GTD Golf Mk5 problems

[ak77]

Hi guys, just wondering if anyone can offer some assistance here. I have had this GTd golf now for 2 years and it seems cursed with electrical issues.
Everything from injector failure to interior lighting. I have ironed out much of it but yesterday the car stopped and wont turn on.

Last thing fixed on the car was the G28 sensor ( replaced 2 months ago. ). this seems to be persistent error together with fuel pump relay error.
Now I have below errors and as car is a non mover. Any help would be appreciated as this car has now cost me a small fortune.


__________________________________________________ _____________________________________

Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 15 16 17 19 25 42 44 46 52 56 62 72 76

VIN: WVWZZZ1KZ8U002011 Mileage: 125670km-78087miles

01-Engine -- Status: Malfunction 0010
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010

-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-018-BMN.clb
Part No SW: 03G 906 018 FC HW: 03G 906 018 FC
Component: R4 2.0l PPD1.2 G 1155
Revision: --H42--- Serial number: VWX7Z0G43NO1FZ
Coding: 0000078
Shop #: WSC 00046 412 00000
VCID: 6BD5F48C4A26DB66B4-803F

1 Fault Found:
000801 - Engine Speed Sensor (G2
P0321 - 006 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 40
Mileage: 125679 km
Time Indication: 0
Date: 2000.00.00
Time: 01:25:49

Freeze Frame:
RPM: 128 /min
Torque: 96.0 Nm
Speed: 0.0 km/h
Time: 0.01 s
Angle: 0.0 ∞
Bin. Bits: 00000000
Bin. Bits: 00000001

Readiness: N/A

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 02E-927-770.lbl
Part No SW: 02E 300 044 L HW: 02E 927 770 AE
Component: GSG DSG 081 1403
Revision: 04608010 Serial number: 00000704301340
Coding: 0000020
Shop #: WSC 44551 111 44551
VCID: 1E33ED58C914FECE63-804B

No fault code found.

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Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No SW: 1K0 907 379 AC HW: 1K0 907 379 AC
Component: ESP FRONT MK60 0101
Revision: 00H11001
Coding: 0023170
Shop #: WSC 00046 412 00000
VCID: 73E5ECEC121603A67C-8027

No fault code found.

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Address 08: Auto HVAC Labels: 1K0-907-044.lbl
Part No SW: 1K0 907 044 BR HW: 1K0 907 044 BR
Component: ClimatronicPQ35 120 1111
Revision: 00120021 Serial number: 00000000000000
Shop #: WSC 00000 000 00000
VCID: 78FFDBC00B7060FE49-802D

1 Fault Found:
00716 - Air recirculation Flap Positioning Motor (V113)
000 - - - Intermittent

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Address 09: Cent. Elect. Labels: 3C0-937-049-30-H.lbl
Part No SW: 3C0 937 049 AJ HW: 3C0 937 049 AJ
Component: Bordnetz-SG H54 2202
Revision: 00H54000 Serial number: 00000007980938
Coding: E58D8F2700041500471400001400000000087F075C00010000 0000000000
Shop #: WSC 00046 412 00000
VCID: 71E9E6E4680A31B68E-8025

Subsystem 1 - Part No: 1K2 955 119 E Labels: 1KX-955-119.CLB
Component: Wischer 140707 020 0501
Coding: 00049109
Shop #: WSC 00046

Subsystem 2 - Part No: 1K0 955 559 AB Labels: 1K0-955-559-AF.CLB
Component: RLS 310806 020 0105
Coding: 00208933
Shop #: WSC 00046

4 Faults Found:
01259 - Fuel Pump Relay (J17)
009 - Open or Short to Ground
Freeze Frame:
Fault Status: 01101001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 214
Mileage: 123632 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 12.30 V
ON
OFF
OFF
OFF
OFF

02092 - Enabling Heated Seat
009 - Open or Short to Ground
Freeze Frame:
Fault Status: 01111001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 214
Mileage: 123632 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 12.30 V
ON
OFF
OFF
OFF
OFF

02399 - Control Circuit for Terminal 30 for Interior Illumination
009 - Open or Short to Ground
Freeze Frame:
Fault Status: 01111001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 214
Mileage: 123632 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
OFF
Voltage: 12.45 V
OFF
OFF
OFF
OFF
OFF

00059 - Terminal 30 for Interior Lighting
012 - Electrical Fault in Circuit
Freeze Frame:
Fault Status: 01101100
Fault Priority: 5
Fault Frequency: 111
Reset counter: 214
Mileage: 123632 km
Time Indication: 0
Date: 2005.09.13
Time: 31:63:63

Freeze Frame:
ON
Voltage: 12.30 V
ON
OFF
OFF
OFF
OFF


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[Transporter]

How good/old is your battery? The 128 rpm while cranking is not good enough to me.

Sent from my SM-N920I using Tapatalk

[Umai Naa!!]

Yep, 280rpm minimum before the injectors will fire.

Have the battery tested.

Also check the wiring for G28 as well. There's a connector down on the inside of the left chassis rail that can often have a broken wire or two at it. Usually for G28, or the coolant temp sensor.

[ak77]

Hey guys, the battery details :

CCA 660
RC130
DIN 65 LH Century ( 12v)

Any thoughts

[JustCruisn]

Hey guys, the battery details :

CCA 660
RC130
DIN 65 LH Century ( 12v)

Any thoughts

Batteries, free delivery and install | RAC Perth WA
RAC will test and replace if needed, often less than retail stores.
Or go to Supercheap/Repco/Battery World etc and ask for a free test.

[ak77]

Below is my Central Electronics Control Module board, what relays should I be looking at for Fuel Pump Relay (J17) faulty.
Just confirming , in case I pulled the wrong 460 one out ? And also which of these should i bee looking at for the interior lighting ?

Error | VW TDI forum, Audi, Porsche, and Chevy Cruze diesel forum

Error | VW TDI forum, Audi, Porsche, and Chevy Cruze diesel forum

[h100vw]

Below is my Central Electronics Control Module board, what relays should I be looking at for Fuel Pump Relay (J17) faulty.
Just confirming , in case I pulled the wrong 460 one out ? And also which of these should i bee looking at for the interior lighting ?

Error | VW TDI forum, Audi, Porsche, and Chevy Cruze diesel forum

Error | VW TDI forum, Audi, Porsche, and Chevy Cruze diesel forum

Opens and shorts more often than not point to power and earth problems. I'd see if it jumps starts, it might sound like it's cranking ok. The difference between 128 and 280 isn't massive to pick by ear.

The spec of the battery doesn't mean much if it's down a cell.

Could be pulling down the voltage enough to stop the fuel pump relay.

[ak77]

hey , the car start same with battery and jump start, its just cuts out and shuts off after turning on 10 sec after....
Sounds like fuel is not reaching .
no clue how to go about this


Al

[Greg Roles]

Very common for the DPF regens to cook a battery over time, and I've had and seen SO many problems like this that all came down to a dead battery - even if it tests fine. I went through several batteries with my MKV GT TDI but I did mess around with small gel batteries that do die quick without a higher charge voltage.

Put a good battery from another car into it, clear all the codes and see what happens. The engine speed sensor is a typical error highlighting a battery that is dying, but it won't stop the car from running ( if you crank it fast enough to start! ).

The fuel pump relay fault was over a thousand kms ago by the screen shot above, but yes your problem seems like fuel...

[ak77]

Update, EGR, whaaaaaat?

I have recently posted issues I had with G28 speed sensor and J17 Fuel pump relay! I diagnosed the problems after car shut off. Lots off this didn't make sense.
Full story here. 01259 - Fuel Pump Relay (J17) MK5 GT TDI golf | VW TDI forum, Audi, Porsche, and Chevy Cruze diesel forum

I now have successfully started the car and drove for hours. I stumbled across a smell. EGR smell!
Basically I discovered that fumes from EGR valve have been blocking the startup/ sucked up the engine. After blanking EGR valve with a home made plate the G28 Sensor code dissipated, gone.
Car runs fine, if not better. More responsive than ever.

My question is, why would the EGR not be read by VCDS and not offer the trouble codes.
Even now that the engine reticulation is blocked, why isn't it spitting out error? Temp/oxygen/volume? Should it not come up on dash as warning?

I have noticed lots of people are blocking the intake to EGR Valve and ebay sells heaps of plates.
Can someone offer a proper way to disable the dreaded EGR function.

Any pro's/con/s why this should be done? or not?

This has created so many issues for me , I cant quite understand why diagnostic software didn't pick on it. Only way I stumbled on it was the smell from the car and sporadic clicking in the valve solanoid after cranking few times.

[Umai Naa!!]

They will log a G28 error if there's prolonged cranking.

I suspect that the EGR failure is allowing unmetered air to enter the combustion chambers, which is affecting start-up.

A diagnostic scanner won't pick up everything. Sometimes you need to think outside the square and apply science and knowledge.

[Greg Roles]

With the EGR blocked, you will get an error and the car will go into distance based DPF regens, so generally every 400kms or less.

Drilling a 7-10mm hole in the plate avoids the error FYI.