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**BrianJ** · 20-06-2012, 07:09 PM

There's a lot of faults there, the simplest thing to do while it is at your house would be to reseat all the fuses and relays, in all fuse boxes including the one under the battery, in case it is caused by a loss of electrical power to some parts, like the relay that controls the vacuum to the turbo. Most of the minor glitches I have had in my kombi have been fixed by reseating the fuses.

I don't guarantee anything because I don't know what the fault is, but this is the easiest thing to try.

Edit: By reseat fuses, I mean to pull each one in turn and press them in again, this will fix any that have a bad electrical connection.

Brian

**Transporter** · 20-06-2012, 08:03 PM

Check the EGR valve. You should also check the engine measuring blocks; MAF, EGR, Boost.
It's harder without hearing it, seeing it. It could be many things. An air leak somewhere? Lose wire, connector?

**The_Hawk** · 20-06-2012, 08:19 PM

According to the VCDS log there is no boost (Charge air pressure; actual value) and it doesn't sound like it's trying to make any.
"Charge pressure control activity" returns a value (in both sensors I can see) which never moves.

**The_Hawk** · 20-06-2012, 08:55 PM

Starting up and idling I have a "clicking" sound from the right side of the engine and the intake pipe is pulsing slightly. Squeezing the pipe and you can feel a small amount of pressure which seems to release on the click. It's me moving my hand, not boost causing that if anyone is wondering... just moving with the pulse.
The click could very well be a valve/solenoid opening and closing.

Video for sound purposes mostly:

[YOUTUBE]V39WTW5O4g4[/YOUTUBE]

[YOUTUBE]w7KJCGRag8g[/YOUTUBE]

**Tuning Dynamics** · 20-06-2012, 09:18 PM

Originally posted by The_Hawk View Post

My wife called me this afternoon telling me the Van is doing strange things and this error came up. She limped it home where it's now parked...

I called the local dealer who says they have no space at all until next Tuesday and no loan cars available until at least then. I did point out that me keeping it at home was sort of pointless when I couldn't drive it and asked if there were any options to get it looked at sooner... the answer was an unconvincing "not really"... I plan an dropping it down anyway in the hope they can find 5 minutes spare to at least make sure it's not a random brain fart of the computer.

Of course, that was the idea before I got home and had a chance to scan it. Seems the CEL is on when you start it, then if you attempt to drive at all (read even reversing out of the driveway), the coil light (looks like a twisted wire) starts flashing and the Engine Fault Workshop message is displayed as white text. Of course the biggest problem is that the turbo does not seem to be spooling up at all.

So this is the results of the scan and I'm wondering WTF? Any suggestions?

Code:

[i](Some non important lines where there is no fault have been removed to fit it in this thread)[/i]
Wednesday,20,June,2012,18:01:37:35849
VCDS Version: Release 11.11.3
Data version: 20120401
--------------------------------------------------------------------------------

Chassis Type: 6N0
Scan: 01 02 03 08 09 10 15 17 19 25 69

VIN: WV2ZZZ7HZAHxxxxxx

01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: Malfunction 0010
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
69-Trailer -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CCHA)       Labels: 03L-906-022-CAA.clb
   Part No SW: 03L 906 022 GF    HW: 03L 907 309 K
   Component: R4 2,0L EDC   H32 9130  
   Revision: 26H32---    Serial number: 00000000000000
   Coding: 01254012232400080000
   Shop #: WSC 23117 959 96126
   ASAM Dataset: EV_ECM20TDI01103L906022GF 002008
   ROD: EV_ECM20TDI01103L906022GF.rod
   VCID: 6FE724D2B6862D1

6 Faults Found:
11901 - Manifold Pressure / Boost Sensor (G31) 
          P0236 00 [032] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 52725 km
                    Date: 2026.14.19
                    Time: 17:10:18

4124 - Sensor Reference Voltage B 
          P0651 00 [032] - Open Circuit
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 52725 km
                    Date: 2026.14.19
                    Time: 17:10:02

4881 - EGR Valve (N18) 
          P1440 00 [032] - Open Circuit
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 17
                    Mileage: 52723 km
                    Date: 2026.14.19
                    Time: 17:06:31

9120 - EGR Sensor 1 
          P046C 00 [100] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 52720 km
                    Date: 2026.14.19
                    Time: 16:15:59

4891 - EGR Valve (N18) 
          P0403 00 [168] - Malfunction
          MIL ON - Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 4
                    Mileage: 52719 km
                    Date: 2026.14.19
                    Time: 16:13:29

4892 - EGR Valve (N18) 
          P0403 00 [168] - Malfunction
          MIL ON - Intermittent - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 4
                    Mileage: 52719 km
                    Date: 2026.14.19
                    Time: 16:13:25

Readiness: 1 2 0 0 0 

-------------------------------------------------------------------------------
Address 02: Auto Trans (J217)       Labels: 0BH-927-711.clb
No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (-----)       Labels: 7E0-907-37x-MK25AXT.clb
   Part No SW: 7E0 907 379 E    HW: 7E0 907 379 E
   Component: ESP MK25A XT  H43 0103  
   Revision: 00H43001    
   Coding: 108724AD09A8089924A2907AAA6216
   Shop #: WSC 02756 790 49152
   VCID: 346DEBBE97204E9

1 Fault Found:
01314 - Engine Control Module 
            013 - Check DTC Memory - Intermittent
             Freeze Frame:
                    Fault Status: 00101101
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 134
                    Mileage: 52725 km
                    Time Indication: 0
                    Date: 2026.14.19
                    Time: 17:10:02

             Freeze Frame:
                    Count: 2048
                    Count: 17
                    Count: 8241
                    Count: 4


-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels: 7E5-907-040.clb
No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels: 7H0-937-08x-09.clb
   Part No SW: 7H0 937 087 B    HW: 7H0 937 087 B
   Component: BCM T5GP H+4  H46 0207  
   Revision: BO046001    Serial number: 0156 044100618
   Coding: A0A0293A0E61240393204000242B8FD40080410F60040000300000000000
   Shop #: WSC 02756 790 00000
   VCID: 336FE8A2922E491

   Subsystem 1 - Part No: 1K0 955 559 AH  Labels: 1K0-955-559-AG.CLB
   Component: RLS 090210 05  54  0403 
   Coding: 03302E

   Subsystem 2 - Part No SW: 7E0 959 801 B    HW: 7E0 959 801 B
   Component: J386__TSG_FT  002 3310 
   Coding: 010000

   Subsystem 3 - Part No SW: 7E0 959 802 B    HW: 7E0 959 802 B
   Component: J387__TSG_BT  002 3310 
   Coding: 000000

   Subsystem 4 - Part No: 7E1 951 171 
   Component: DWA-Sensor 00  001 0104 
   Coding: 000000

   Subsystem 5 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H05 1501 
   Coding: 000000

   Subsystem 6 - Part No: 7E1 951 171 
   Component: DWA-Sensor 00  001 0104 
   Coding: 000000

1 Fault Found:
03587 - Control Circuit for Starter Lock Lock 
            007 - Short to Ground - Intermittent
             Freeze Frame:
                    Fault Status: 00100111
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 126
                    Mileage: 52394 km
                    Time Indication: 0
                    Date: 2026.14.13
                    Time: 09:57:55


-------------------------------------------------------------------------------
Address 10: Park/Steer Assist (J446)       Labels: 7E0-919-475.clb
No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels: 5K0-959-655.clb
No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels: 5K0-920-xxx-17.clb
No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels: 6N0-909-901-6R.clb
No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels: 5K0-920-xxx-25.clb
No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer (J345)       Labels: 1K0-907-383-MY8.lbl
No fault code found.

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

First thing i would do is reset the computer, even disconnect battery for 30 mins after clearing codes then run it.
Check them again after the light comes one.
There is a little known fault with a wiring harness that is used which can cause the boost pressure sensor to show implausable signal.
It does however look as though its more directed at EGR based on the times and kms when the faults showed.
Could well be blocked EGR causing issues after , but i would go through them one at a time.
The wiring harness is about a 90 minute change from the dealer and a 50 dollar part.
They had no idea on my skoda when it went, got the lights and limp mode and implausable signal error.

**The_Hawk** · 26-06-2012, 06:51 PM

As of yesterday it's all back and running nicely, to their credit the local dealer took the car in Thursday morning checked it out and ordered parts, fit them on Friday only to need another part which came in Monday. Yes it would have been nice to get it back for the weekend, but like I said they did get me back on the road much earlier than the Tuesday they originally quoted as first available slot.

The invoice talks about a short in the EGR cooler and references part # 03L 131 512 CB (as well as a few gaskets and one of the electrical plugs):

Fingers crossed all is well from here on out

**Umai Naa!!** · 26-06-2012, 07:49 PM

The technician is probably on stress leave after replacing that.

I've done one. They suck.

**buzuki** · 27-06-2012, 06:53 PM

too right, also done one

**Foxpuppet** · 09-07-2012, 07:53 AM

Seems I have the same drama right now sitting on the side of the road at terrey hills with a tow truck enroute. Driving home from holidays on Saturday , the same error came up about 50 km from home after driving for about 5 hours. So I pulled over turned the van off, then ignition on, and the fault was cleared. Was going to drop by Vw after work today but the van beat me to it. I drove about 5km in limp mode then decided to pull over. Can't risk damaging my only business vehicle! Seems to be similar issue with turbo/no boost. Although that's just me speculating.... Got no idea on TDi's really. Is it safe to drive in limp mode for long?

**IN2VWS** · 09-07-2012, 04:21 PM

Mine had the same problem. After pulling over a few times and switching the engine off, I was good to go again. My dealer said it was ok to drive until they could fix it. The fault only came back after long drives.
They fitted a new EGR valve, and it hasn't happened again.

**Foxpuppet** · 09-07-2012, 06:44 PM

They got the van at 1130am and I called them at 330pm to check on the progress but was told they had not been able to diagnose. Not sure if it meant they had not looked at it yet or they actually didn't know whats happened yet. I thought the whizbang electronicc vagcom gear would diagnose it quickly. Hopefully they can fix it ASAP cause I'm carrying a crapload of gear in my wifes 323 until they do

**Foxpuppet** · 10-07-2012, 04:19 PM

Confirmed today it's egr valve, but I'm looking at 3 days until they get the parts. The service guys would not tell me so I went and spoke to the guys in the workshop. They were Much more helpful. Is this a common fault? Lucky my Vw assist gets me a hire van!

**IN2VWS** · 10-07-2012, 06:49 PM

I am beginning to suspect this is a common fault.
I was at the dealers last week. Said hi to the guys in the service department. During our chat, they asked "yours has already had the EGR done, hasn't it?". Not sure if they asked this because it is common, or if they remembered when I had the problem.

**Foxpuppet** · 21-07-2012, 01:27 PM

just got it back on wednesday afternoon. 10 days to get the parts and fit... seemed a little long, but i am so glad to have it back. my question now is how long should i expect this to last? what happens to the warranty on this item when the original expires next year?

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