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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKV-A5 Golf/Jettas

VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old December 14th, 2011, 11:07   #1
walt_mink
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Default G235 EGT Sensor Replacement Procedure

Hi all,

So, my '09 JSW started throwing a code a couple of days ago. A quick scan with an ODBII scanner showed a P0544, and I followed that up with a borrowed VAG-COM scan (below). It looks pretty cut and dry - the probe is TU.

Can someone please help me with the procedure to replace the G235 EGT sensor? I think I see which one it is, but it looks pretty wedged in there. Has anyone done it, and could you tell me what all you had to pull off to get the probe out?

Thanks!

-------------------------------------------------------------------------------
Address 01: Engine (CBE) Labels: 03L-906-022-CBE.clb
Part No SW: 03L 997 016 N HW: 03L 906 022 J
Component: R4 2,0L EDC G000SG 8680
Revision: 12H01--- Serial number: VWX7Z0I424B049
Coding: 0050072
Shop #: WSC 00066 000 00000
VCID: 3D5FEA20646A8EC

2 Faults Found:
001348 - Sensor 1 for Exhaust Temp Bank 1 (G235)
P0544 - 000 - Circuit Malfunction - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 2
Mileage: 61598 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
Voltage: 11.48 V
Temperature: 4.5C
Temperature: 930.0C
Temperature: 0.0C
Temperature: 0.0C

001348 - Sensor 1 for Exhaust Temp Bank 1 (G235)
P0544 - 000 - Circuit Malfunction - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 2
Fault Frequency: 3
Mileage: 61598 km
Time Indication: 0
Date: 2000.00.00
Time: 09:13:37

Freeze Frame:
RPM: 989 /min
Speed: 0.0 km/h
Voltage: 12.31 V
Temperature: 4.5C
Temperature: 930.0C
Temperature: 6.0C
Temperature: 0.0C

Readiness: 1 1 0 0 0

-------------------------------------------------------------------------------
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Old December 14th, 2011, 13:14   #2
Rather Be Biking
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I have the same problem. Trying to get VW to take responsibility as I'm 10 minutes out of warranty.
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Last edited by Rather Be Biking; December 14th, 2011 at 13:28. Reason: remove large pasted text of VCDS printout - to shorten post
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Old December 14th, 2011, 13:16   #3
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We're not that far off. I'm about 2,600 miles outside of warranty. Figures, right?
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Old December 14th, 2011, 13:25   #4
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Best as I can tell, looking at the shop manual, there are two of these sensors next to each other. Don't quite know which one to replace. Dealer say "Black one." This link here, which I got from another thread, shows prices for an orange or a brown one. This is why the car is at the dealer. Plus it does look tight. I was hoping that the oxygen sensor, which is visible on top of the DPF, was the G235, but no such luck, as I later realized it was the 02 sensor.

http://www.ezvwparts.com/partlocator...layCatalogid=0

I had the winter intercooler kit installed last month, but I can't see how there would be a connection between that installation, and this dead sensor. I'm at just under 36k miles, but two months over on my warranty.
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Last edited by Rather Be Biking; December 14th, 2011 at 13:26. Reason: add link
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Old December 14th, 2011, 13:38   #5
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I'm a bit embarrassed to admit it, but I didn't know the powertrain was 5yr/60,000 for this car. I thought it expired at 3/36. That being true, it looks like I'm covered, so my laziness can continue - I'm off to call my dealer.
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Old December 14th, 2011, 13:50   #6
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Powertrain warranty does not cover this. Neither does the Emissions warranty.


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Originally Posted by walt_mink View Post
I'm a bit embarrassed to admit it, but I didn't know the powertrain was 5yr/60,000 for this car. I thought it expired at 3/36. That being true, it looks like I'm covered, so my laziness can continue - I'm off to call my dealer.
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Old December 14th, 2011, 13:54   #7
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Huh. You think? It sure seems to be part of the powertrain to me. I'll have to go look up the specifics.
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Old December 15th, 2011, 04:01   #8
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Quote:
Originally Posted by Rather Be Biking View Post
Powertrain warranty does not cover this. Neither does the Emissions warranty.

you could argue up and down with the dealer, if you have a good report with them they might go to bat for you.

I had rear door lock latch thingy replaced free of charge at 42K becuse the dealer felt it shouldn't have failed this early.

btw for getting at the EGT does the DPF have to come off? engine dropped? how easy are you guys looking at these probes?
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Old December 15th, 2011, 07:02   #9
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Not very easy to get to, but easy enough. I believe you neede to remove a heat shield on top of the DPF. It's tight, and the probles are on the side facing the engine block. Dealer says $138 labor, so it can't be too hard.


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you could argue up and down with the dealer, if you have a good report with them they might go to bat for you.

I had rear door lock latch thingy replaced free of charge at 42K becuse the dealer felt it shouldn't have failed this early.

btw for getting at the EGT does the DPF have to come off? engine dropped? how easy are you guys looking at these probes?
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Old December 15th, 2011, 15:15   #10
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It appears that VCDS is a better system than the VW shop computer, or my dealer is full of, which seems more likely. Anyway, VCDS was able to show me live readings from each sensor, and only one was giving a bad reading. The dealership, by comparison, claimed they could not tell which sensor was bad until they tested four of them manually. Cost for "diagnosis" is $135 (higher that the $48.95 they initially quoted), PLUS another $135 to, well, return to the same place and actually swap a sensor out. VW, however, will comp the part as a courtesy -- so it's kind of a wash. VW was ok, but the dealer is apparently jumping into the void and grabbing some of the cash that would otherwise have gone to VW for the part.

Or the dealer is telling the truth and this is a more complicated job than it seems.
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Old December 16th, 2011, 04:18   #11
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they probably had the stance:

we can tell where there's a issue from the code pulled, but if you want us to "dig into" the problem more (IE look up the code then scan the car to find which of the sensors was bad) we'd then have to charge you additional for "trouble shooting".

Pulling codes and trouble shooting are two different things in their book.
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Old December 16th, 2011, 11:10   #12
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Is it possible to disconnect one sensor and run VCDS output test to identify which is G235? That would be my approach.
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Old December 21st, 2011, 08:39   #13
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Default New sensor - mileage up

I have the new sensor now installed. I noticed a significant mpg increase -- this after watching it inch down over the past 8 months or so. My theory is that the sensor was sending bad readings for quite a while, but not bad enough to be implausible and light a CEL. Would a false reading from this sensor (exhaust temp before turbo) cause a mileage drop?
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Old December 21st, 2011, 08:59   #14
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sure, it could lean out the fuel or air or something to try and drop the EGTs, or vice versa, epecially for regens!
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Old March 26th, 2012, 14:47   #15
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I forgot to reply to this back then. My dealer replaced the part of what they call 'good will' warranty and all is well. I like Roger Jobs in Bellingham, WA - nice folks.

I'm still getting sort of crap mileage and some stumbling, but I think that might be my MAF going TU. I'm working on getting a VAG-COM hooked up to verify that now.
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