Help.. ABS, ESP then Steering and tyres warning lights on 2006 Polo GTI

[Paazuzu]

Flick up the black cover next to those blade fuses, where you'll find some high amp ones with 10mm nuts on each end. These are often broken, hairline cracks, causing intermittent failures.

Gavin

Thanks Gav - will check it out ASAP. Want to get this sorted before I see you for a stage 1 tune!

[Paazuzu]

Normally this problem is the power steering (pump) unit - internal short pulls the voltage down on that entire bus. If you check the wiring diagram, you will see that is the first point the voltage passes through.

I would almost bet beer on it.

Betting beer on it eh? That's a big call

I'll check the fuses then will get someone to look at the pump for me.

[brad]

Sikman came & picked up the VCDS cable at my place tonight. We did a quick scan & it has many codes which he saved as a txt file. Maybe he can post it here for further diagnosis.

I'm pretty sure most of them are collateral to whatever the main problem is. The battery is a fairly new NRMA unit but that doesn't mean much.

Voltage pulls down to 10.6v at start-up with headlights on.

I'm also thinking he should clear the codes & see what comes back now he has scanned them but maybe that's not the smartest idea?

[sikman]

First off I must thank Brad for lending me his VAGCOM cable, met him last night top bloke and very helpful and knowledgeable..

I will post all my codes below, when I got home last night I cleared the codes and drove around the block 3 times, stopped and turned steering hard lock left and right multiple times, stop and started car again, hit some roundabouts, etc and then checked for codes and nothing came up beside 1 errors ""01596 - Motor for Outside/Recirculated Air Flap (V154) " my aircon works on all speeds and cool air comes out...

I also drove the car to work today and so far trouble free.

I rang up NRMA and spoke to the tech and he reckons 99% that its got something to do with the alternator/wiring to it as when the car is running it should be up in the 14V range but my car is lucky to see 13V max

Codes:
Monday,24,February,2014,19:30:24:29321
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.0.0
Data version: 20130910


VIN: WVWZZZ9NZ6Y178012 License Plate: NXM26G
Mileage: 83470km-51865mi Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 9N (9N - VW Polo (2002 > 2010))
Scan: 01 02 03 08 09 15 17 19 25 37 44 45 46 56 76

VIN: WVWZZZ9NZ6Y17XXXX Mileage: 83470km/51865miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: None
Part No: 06A 906 032 TL
Component: 1.8l R4/5VT G 0040
Coding: 11500
Shop #: WSC 00788
VCID: 7BFE656B6997E9C6C11-513C
WVWZZZ9NZ6Y17XXXX VWZ7Z0F3286050

3 Faults Found:
17936 - Camshaft Timing Adj. Bank1 (N205)
P1528 - 35-10 - Open Circuit - Intermittent
17840 - Secondary Air Injection Solenoid Valve (N112)
P1432 - 35-10 - Open Circuit - Intermittent
17695 - Boost Pressure Control Valve (N249)
P1287 - 35-10 - Open Circuit - Intermittent
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: None
Part No SW: 6Q0 907 379 AR HW: 6Q0 907 379 AR
Component: ESP 8.0 front H02 0002
Revision: 00000000 Serial number: 00000000000000
Coding: 0000269
Shop #: WSC 00788 785 00200
VCID: 8D1ABBB3972357766F5-513C

2 Faults Found:
01201 - ABS Pump Supply Voltage
000 - - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 1
Fault Frequency: 2
Reset counter: 203
Mileage: 83440 km
Time Indication: 0

00532 - Supply Voltage B+
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 3
Fault Frequency: 2
Reset counter: 203
Mileage: 83462 km
Time Indication: 0


-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 6Q0-820-045.lbl
Part No: 6Q0 820 045
Component: Klimaanlage X0840
VCID: EAD0D02F960DE04EAA7-513C

1 Fault Found:
01596 - Motor for Outside/Recirculated Air Flap (V154)
30-10 - Open or Short to Plus - Intermittent

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 6Qx-937-049-C.lbl
Part No: 6Q1 937 049 D
Component: 00BK BN-SG. 1S34
Coding: 25742
Shop #: WSC 00788
VCID: 3C7CA6772C192EFE88B-513C

2 Faults Found:
01309 - Power Steering Control Module (J500)
49-10 - No Communications - Intermittent
01598 - Drive Battery Voltage
07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 F
Component: 26 AIRBAG VW61 0N06 0003
Coding: 12854
Shop #: WSC 00788
VCID: 2756691BC59F9D26F59-513C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 6Q0-920-xxx-17.lbl
Part No: 6Q0 920 823 N
Component: KOMBI+WEGFAHRSP VDO V02
Coding: 03744
Shop #: WSC 00000
VCID: 3D7AAB73370327F6BF5-513C
WVWZZZ9NZ6Y178012 VWZ7Z0F3286050

1 Fault Found:
01309 - Power Steering Control Module (J500)
49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: 0B7L GATEWAY CAN 1S34
Coding: 00014
Shop #: WSC 00788
VCID: F0E4C247B0D11A9EE43-513C

1 Fault Found:
01309 - Power Steering Control Module (J500)
49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 6Q0-423-156.clb
Part No: 6Q0 423 156 AB
Component: LenkhilfeTRW V270
Coding: 10120
Shop #: WSC 00788
VCID: 6FE6413B2DEF85667D9-513C

2 Faults Found:
00566 - Steering Assistance Operation
27-10 - Implausible Signal - Intermittent
01288 - Terminal 30; Steering Assist
07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 45: Inter. Monitor Labels: 6Q0-951-171.lbl
Part No: 6Q0 951 171 C
Component: Innenraumueberw. 0020
VCID: 3260884FFE5DE88E527-513C

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 6Q0-959-433.lbl
Part No: 6Q0 959 433 E
Component: 63 Komfortgerát 0002
Coding: 00016
Shop #: WSC 00788
VCID: 3D7AAB73370327F6BF5-4B00

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No SW: 6Q0 035 152 A HW: 6Q0 035 152 A
Component: Radio BVX 005 0004
Revision: 00005000 Serial number: VWZ1Z5F8988225
Coding: 0040400
Shop #: WSC 00788 785 00200
VCID: 28546A279881925EFC3-513C

No fault code found.

End ---------------------------------------------------------------------

[sikman]

Update:

Went out and tested battery again and now for some reason while car is running battery volts are back to around 14V....not sure what to think now as previously it would only go to 13V max

[h100vw]

Update:

Went out and tested battery again and now for some reason while car is running battery volts are back to around 14V....not sure what to think now as previously it would only go to 13V max

Current that the alternator is putting out is an important factor that lots of folk over look. It could be there was a big short like Guy believes. If the draw is hard enough voltage will drop.

Most of those codes look like a flat battery could have caused them. Maybe the alternator isn't as good as it could be, duff rectifier or a high resistance in the circuit that you were measuring through, skewing the results. A bad earth or battery clamp??

[sikman]

Normally this problem is the power steering (pump) unit - internal short pulls the voltage down on that entire bus. If you check the wiring diagram, you will see that is the first point the voltage passes through.

I would almost bet beer on it.

It might be as bad as Guy_H is describing, will continue to investigate....

Bad news, came home from work today, turned hard right to get into driveway and then back hard left to reverse out and guess what, power steering went funny again, I could also hear a pump noise and a thud thud thud constant noise pulsing, turned car off and back on again and it cleared. Will pull error codes later.

[CJHOOKR]

Bit busy at work at the moment to go into detail but a similar thing happened to me last week, lights on the dash came on while driving so I pulled over immediately and turned the car off and on to find they were still there. Turned the car off, fiddled with the battery and let it sit for 5 mins... turned the key again and clock had been reset but otherwise was back to normal until I got home where it happened to me again. Hasn't happened since though.

I'm going to start by replacing the Earth strap after reading this:

http://www.vwwatercooled.com/forums/f127/electrical-gremlins-%3D-faulty-ignition-switch-70962.html

[Jmac]

The alt to batt positive cable can get brittle and cause resistance which can also cause dramas. Allsorts of stuff can cause this , with the diagram you can check what all the open circuit faults are and you will find they are all linked to a common source. Ah my favourite type of faults. Anyway good luck

Jmac

[sikman]

More updates:
Loss of electric assistance Steering and most lights on the dash still coming on, its really hard to turn full lock to pull out of a parking space, it was intermittent before every few days but now it happens all the time, yesterday I drove home for 30mins with no power steering, that was fun.

New issues and new fault has comes up, while stopped at Red lights the car engine will hesitate and then BOOM everything is cut off and lose all ignition/engine, quick flick of the key and back to idle, has happened 3 times since yesterday.

When car is in a SPASTIC state I check battery volts and its at 12.8V, turn key off then back on again car starts with no errors and now has 14V. Something is pulling voltages down on the system to cause all these errors, and when it gets bad will pull enuff to shutdown the whole car.

I've also noticed that when it shuts down my Trip meter reset back to 0km, Will be taking car to my mechanics today for a full inspection of electrical wiring, earth, fuses, etc.....

Also new code appearing:
Address 46: Central Conv. Labels: 6Q0-959-433.lbl
Part No: 6Q0 959 433 E
Component: 63 Komfortgerát 0002
Coding: 00016
Shop #: WSC 00788
VCID: 3D7AAB73370327F6BF5-4B00


1 Fault Found:
00849 - S-contact at Ignition/Starter Switch (D)
25-10 - Unknown Switch Condition - Intermittent

[sikman]

Bit busy at work at the moment to go into detail but a similar thing happened to me last week, lights on the dash came on while driving so I pulled over immediately and turned the car off and on to find they were still there. Turned the car off, fiddled with the battery and let it sit for 5 mins... turned the key again and clock had been reset but otherwise was back to normal until I got home where it happened to me again. Hasn't happened since though.

I'm going to start by replacing the Earth strap after reading this:

http://www.vwwatercooled.com/forums/...tch-70962.html

Hey, thanks for the link, that guys issues are almost exactly like mine, will check ignition switch first since I got that error but will look at checking/replacing the earth strap

[Paazuzu]

Hey, thanks for the link, that guys issues are almost exactly like mine, will check ignition switch first since I got that error but will look at checking/replacing the earth strap

Hey sikman

Did you end up sorting this issue out?

[brad]

snap!
Was only wondering about it on the commute in this morning. Wouldn't mind getting my cable back as I've got some TPMS fiddling I want to try out.

[sikman]

Hey sikman

Did you end up sorting this issue out?

No, car is at mechanics for the last 2 weeks but he has not touched it yet, busy busy and plus he is my friend

[sikman]

snap!
Was only wondering about it on the commute in this morning. Wouldn't mind getting my cable back as I've got some TPMS fiddling I want to try out.

I call you today to organise return of cable back to you