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Discussion Starter #1
I have a 99.5 jetta ALH that I have gone completely over, but but have several problems that need attention.
These are the list of items that have been replaced, after this vehicle had a turbo seize.
First of all while replacing the glow plugs I snapped the head off of #4 GP, Not a biggie I already have to replace the turbo and clean the intake and the timimg belt was due for change as well so I'll pull the head. had the head serviced GP extracted and completely replace all intake/exhaust and a 2 hole head gaskets that it had previously, Completely cleaned the entire intake system, and intercooler.
replaced the cam followers. While the head was off and checking the cylinder bores there was still the original cross hatch pattern. I don't think that s to uncommon for high milage diesels the last cummins engine I rebuilt still had the cross hatch pattern in the bores w 260k on the clock.
I replaced the timing belt, Idlers, tensioners, water pump and front main seal because of leak.
Next was the flywheel clutch upgrade to a g60 flywheel kit. while doing the trans was out I went ahead and replaced the front struts, bushings, rotors, brakes, and cleaned and replacked all the cv joints and replaced the boots.
I checked the timing with the vag com and it is dead on without adjusting.
Also noted this has the ccv mod, and egr delete.
I drove it for one day and everything seemed to be functioning properly, except there was no check engine light. I handed over to my son for him to drive and after a couple of days he says the turbos quits boosting sometimes until he restarts the car. then a couple of days later he gets stranded it just died on the highway. I figured it was maybe the water in fuel or the fuel filter has a restriction I installed a inline pump to it a while back. Can the screen in the tank cause a restriction?.
I replaced the filter and got it going again. now he's on his second tank of fuel and the key won't disable the alarm. I looked at the wires as some people experience wires fraying causing this but everything looked OK on this one. I put the door panel back on the the key would disarm the alarm. turn around to check it after installing the panel screws and now the alarm won't enable. but at least its drivable.
I get a call later that evening and he is stranded in the same identical place as before after driving about 60 miles. There is still fuel in the clear line going to the IP. I replaced the gas cap does it matter if it is a vented one or not?
I figure the turbo actuator need adjusting, I don't know why the cel light is not on. Before i did all this work it stayed on because of the ccv mod, and now I've deleted the egr as well. I haven't had a chance to pull the codes yet, but will do so when I get it home.
 

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Well kit sounds like you've had a list of problems and more keep appearing.

I'm not sure which VAG-COM you use but with the later VCDS you can check the function of individual components seperately. You can activate all dash warning lights to see if they operate. You can activate the door locks/alarm and it shows operating/activated or what ever.

Can the screen in the tank cause a restriction?
What screen, do you mean the baffle plates?

replaced the gas cap does it matter if it is a vented one or not?
All tanks have to be vented in some way. As the fuel is being removed air has to be replaced else a vacuum will be created then no fuel gets through. Now this will depend on the system, most petrol/diesel system will have a Charcoal filter is fitted in the fuel tank breather system near the top of the filler neck. It's purpose is to catch all the nasty fumes that leave the fuel tank when you fill up, so this is controlled venting.

If your cap isn't vented then just drive it around, if it doesn't stop then the Charcoal filter must be working. If it does stop then get out and remove the cap allowing air to enter and try it again.

I get a call later that evening and he is stranded in the same identical place as before after driving about 60 miles.
Tell him to change his route. :laugh:
 

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Discussion Starter #3
Here is the vag com scan

VCDS Version: Release 10.6.3
Data version: 20101206

Sunday,15,May,2011,11:08:00:09458

Chassis Type: 9M - VW Jetta IV
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

Mileage: 464700km/288751miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: 1,9l R4 EDC G100SG 2143
Coding: 00002
Shop #: WSC 06482
VCID: 5AB19B0FEC99

5 Faults Found:
17664 - Engine Coolant Temp Sensor (G62): Open or Short to Plus
P1256 - 35-00 - -
17564 - Manifold Pressure Sensor (G71): Open/Short to Ground
P1156 - 35-00 - -
17569 - Manifold Temp Sensor (G72): Open or Short to Plus
P1161 - 35-00 - -
17971 - Quantity Adjuster (N146): Lower Limit Reached
P1563 - 35-00 - -
17762 - Modulating Piston Movement Sensor (G149): Electrical Malfunction
P1354 - 35-10 - - - Intermittent
Readiness: 1 5 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1J0-907-37x-ABS.lbl
Part No: 1J0 907 379 G
Component: ABS 20 IE CAN 0001
Coding: 03504
Shop #: WSC 00066
VCID: 356B28B325C7

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1J0-909-60x-VW3.lbl
Part No: 1J0 909 609
Component: C AIRBAG VW3 SG 0002
Coding: 00067
Shop #: WSC 00066
VCID: ECDD4DD7B60D

1 Fault Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-919-xxx-17.lbl
Part No: 1J0 919 951
Component: A4-KOMBIINSTR. VDO V55
Coding: 06242
Shop #: WSC 00000
VCID: EDDB40D38D17

No fault code found.

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Address 46: Central Conv. Labels: 1J0-959-799.lbl
Part No: 1J0 959 799 AJ
Component: 61 Zentral-SG Komf. 0001
Coding: 04096
Shop #: WSC 00066
VCID: 86091F7F88A1

Part No: 1J1959801C
Component: 61 Tõrsteuerger. FS0001r

Part No: 1J1959802D
Component: 61 Tõrsteuerger. BF0001r

Part No: 1J4959811C
Component: 61 Tõrsteuerger. HL0001H

Part No: 1J4959812C
Component: 61 Tõrsteuerger. HR0001r

4 Faults Found:
00953 - Interior Light Time limit
25-10 - Unknown Switch Condition - Intermittent
00956 - Key 2
09-00 - Adaptation Limit Surpassed
01358 - Internal Central Locking Switch; Driver Side (E150)
27-10 - Implausible Signal - Intermittent
00914 - Window Regulator Switch; Rear Left; Driver (E53)
27-10 - Implausible Signal - Intermittent

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

The coolant temp reads correct not sure why it show up, unless theres 2 sensors
The CES light is on , the glow plug light blinks continually, but I dont have the harness on yet.
Is there a way to test the MAP sensor, Mtemp sensor Coolant Sensor and not sure of the other 2
Quantity Adjuster, and Modulating Piston Movement Sensor.
Internal Central Locking Switch may be why the alarm doesn't set using the key but works with the remote. I don't understand why the turbo boost goes into limp mode, but I guess with this combination of codes you would expect to be some issues.
I got it to start, took about 30-45 seconds of cranking time, and at first it felt like is was missing and sputtering and after about 30 seconds idling it cleared up.
I drove it home with no issues about 16 miles. and did this scan. where do I start
 

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VCDS Version: Release 10.6.3

I got it to start, took about 30-45 seconds of cranking time, and at first it felt like is was missing and sputtering and after about 30 seconds idling it cleared up.
I drove it home with no issues about 16 miles. and did this scan. where do I start
Well if your using Release 10.6.3 then I would say your using VCDS not VAG-COM, it was renamed to VCDS in 2008.

Driving it for 16 miles this will depend on how much fuel is in the tank? The less fuel in the tank there is more air space in the tank so it will take longer to show if its fuel starvation before any vaucuum is created. Its a suck it and see over that part.

As I said previously you can test each component with VCDS to see if it performs correctly. Now I'm no VCDS expert I've only had it 5 months so I've clicked a few button to see what it shows.


VAG Error Code: 17664
EOBD II Error Code: P1256

Fault Location:
Engine coolant temperature (ECT) sensor (G62) - open circuit/short to positive

Possible Cause:
Wiring open circuit/short to positive.
Engine coolant temperature (ECT) sensor (G62).


VAG Error Code: 17564
EOBD II Error Code: P1156

Fault Location:
Manifold absolute pressure (MAP) sensor (G71) - open circuit/short to earth

Possible Cause:
Wiring open circuit/short to earth.
Manifold absolute pressure (MAP) sensor (G71).


VAG Error Code: 17569
EOBD II Error Code: P1161

Fault Location:
Intake air temperature (IAT) sensor (G42) - open circuit/short to positive

Possible Cause:
Wiring open circuit/short to positive.
Intake air temperature (IAT) sensor (G42).


VAG Error Code: 17971
EOBD II Error Code: P1563

Fault Location:
Fuel quantity adjuster - lower stop value

Possible Cause:
Fuel quantity adjuster blocked/defective.
Lower stop value reached.


VAG Error Code: 17762
EOBD II Error Code: P1354

Fault Location:
Fuel quantity adjuster position sensor

Possible Cause:
Wiring.
Fuel injection pump.


VAG Error Code: 00532

Fault Location:
Engine control module (ECM) - supply voltage

Possible Cause:
Fuse.
Alternator.
Battery.
Current draw with ignition OFF.
Engine control (EC).
Relay.
Wiring.


EOBD II Error Code: 00953

Fault Location:
Interior Light Time Limit: Unknown Switch Condition

Possible Cause:
Wiring/Connectors to Interior Light(s) faulty.
Interior Light(s) faulty.

Possible Solutions:
Check Wiring/Connectors to Interior Light(s).
Check Interior Light(s).


EOBD II Error Code: 00956

Fault Location:
Key 2: Adaptation Limit Surpassed


Possible Cause:
Remote control not working.

Key not matched.
Key operated more than 200 times while out of range.

Possible Solutions:
See vehicle specific page for synchronisation/adaptation procedures.


EOBD II Error Code: 01358

Fault Location:
Internal Central Locking Switch: Driver Side (E150): Implausible Signal


Possible Cause:
Wiring and/or Connectors faulty.

Possible Solutions:
Check Wiring and/or Connectors.
Check Measuring Blocks.


EOBD II Error Code: 00914

Fault Location:
Window Regulator Switch; Rear Left (E53): Implausible Signal

Possible Cause:
Wiring/Connector(s) to Window Regulator Switch; Rear Left (E53) faulty.
Window Regulator Switch; Rear Left (E53) stuck.
Window Regulator Switch; Rear Left (E53) faulty

Possible Solutions:
Check Wiring/Connector(s) to Window Regulator Switch; Rear Left (E53).
Check Window Regulator Switch; Rear Left (E53).
Check Meas. Value Blocks (MVB) for Plausibility.

As taken from my http://www.myturbodiesel.com/forum/f9/free-eobd-ii-error-codes-software-2919/
 

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At least in the US, the diesel fuel cap is different because they don't have the carbon canister system to capture and burn the vapors that gas cars do.

Without chip tuning, the EGR delete will definitely throw some codes and set the check engine light. It will not cause running problems with the car though.

To compare MAP, go into the measuring blocks in the engine module. There should be a screen with boost requested by the ECU and boost actual measured. You can graph these as well. Some spikes are normal but they should level out.

Some of the codes might suggest injection pump problems but you said timing was spot on and when you drove it first, it was fine.

The alarm problems might be related to a door module problem. This is very common, the microswitch in the door goes bad and the car doesn't know if a good key was turned to unlock the door or if the door was opened.
 

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Discussion Starter #6
Cleaned connectors and cleared codes

I cleaned the connectors and cleared the codes, drove for aprox 10 miles it ran normal except after about 4 miles the boost gets disabled but will work again after the restarting the engine. i did this three time within the 10 miles I drove. I rescanned and getting these codes, I'm not wooried about the Glow Plug code right now. unsure about the charge pressure though.
I'd like to work the problems with the engine first so is there a surefire way to check the MAF
Also I don't have a way to log with the VCDS as my laptop battery won't hold a charge for more that 2 min.


VCDS Version: Release 10.6.3
Data version: 20101206

Sunday,15,May,2011,21:17:49:09458

Chassis Type: 1J - VW Golf/Bora IV
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

Mileage: 464740km/288776miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-018-AGR.lbl
Part No: 038 906 018 EB
Component: 1,9l R4 EDC G100SG 2143
Coding: 00002
Shop #: WSC 06482
VCID: 5AB19B0FEC99

3 Faults Found:
17552 - Mass Air Flow Sensor (G70): Open or Short to Ground
P1144 - 35-00 - -
16764 - Glow Plug/Heater (Q6) Circuit: Malfunction
P0380 - 35-10 - - - Intermittent
17958 - Charge Pressure: Control Deviation
P1550 - 35-10 - - - Intermittent
Readiness: 1 3 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1J0-907-37x-ABS.lbl
Part No: 1J0 907 379 G
Component: ABS 20 IE CAN 0001
Coding: 03504
Shop #: WSC 00066
VCID: 356B28B325C7

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1J0-909-60x-VW3.lbl
Part No: 1J0 909 609
Component: C AIRBAG VW3 SG 0002
Coding: 00067
Shop #: WSC 00066
VCID: ECDD4DD7B60D

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-919-xxx-17.lbl
Part No: 1J0 919 951
Component: A4-KOMBIINSTR. VDO V55
Coding: 06242
Shop #: WSC 00000
VCID: EDDB40D38D17

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1J0-959-799.lbl
Part No: 1J0 959 799 AJ
Component: 61 Zentral-SG Komf. 0001
Coding: 04096
Shop #: WSC 00066
VCID: 86091F7F88A1

Part No: 1J1959801C
Component: 61 Tõrsteuerger. FS0001F

Part No: 1J1959802D
Component: 61 Tõrsteuerger. BF0001r

Part No: 1J4959811C
Component: 61 Tõrsteuerger. HL0001r

Part No: 1J4959812C
Component: 61 Tõrsteuerger. HR0001H

1 Fault Found:
01358 - Internal Central Locking Switch; Driver Side (E150)
27-10 - Implausible Signal - Intermittent

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

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Other than checking the major engine grounds, I would buy an inverter that runs off the cig lighter to keep the laptop battery charged. It's cheaper than throwing parts at it and you already have VCDS.
 

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Discussion Starter #8
Engine ground locations?

Where are the engine ground locations,
Also the snow screen was totally plugged, the brake vacuum line was cracked
I replace all vacuum lines. I was doing some solenoid test with vcds and when checking
The egr solenoid I could hear it , the n75 on the other hand I couldn't hear any thing.
I checked the voltage at the n75 connector at 12vdc. The resistance on both solenoid valve was 15.6 ohms. I switch n75 and the egr to test drive the next day, no turbo and I get short or open code for both solenoids.
 
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