No start after relay 109 replacement

Hello could use some help from the gurus on MK4's


2001 Jetta TDI auto to 5spd conversion (10k flawless miles since the swap).
Initial condition last week stalled while driving. Would not restart. No glow plug light. Cranks over fine.

Replaced 109 relay. Had glow plug light and car started. Ran ~2 minutes and died. Sounds completely normal when running.

Cleared codes and have glow plug light again. Started up and ran for 3 days before doing the same thing again. Swapped out with another 109 relay same symptoms. Now this time no glow plug light will not start.



Troubleshooting performed:
With 109 relay removed I have 12V at red wire.
With 109 relay removed 0V at blue wire.
Fuse 29 12.4V with key on.
Fuse 34 10.5V with key on.
Fuse 43 12.2V with key on.
Fuse 32 5.7V with key on.
Fuse 37 0v.
Fuse 29 12.4V key on.

Connections at relay socket are good have not pushed out.



Any other suggestions? VCDS scan from this morning. Don't know why all the auto transmission faults now never had that before as I have been running the 5spd for 10K miles in it now. Thanks.



Thursday,18,April,2019,09:37:52:25565
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 18.9.1.0
Data version: 20190114 DS296.0
www.Ross-Tech.com


Chassis Type: 9M - VW Jetta IV (1998 > 2014)
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
75 76

Mileage: 348890km-216790miles
-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 01M-927-733.lbl
Part No: 01M 927 733 KA
Component: AG4 Getriebe 01M 4761
Coding: 00000
Shop #: WSC 00000
VCID: 79F25D2E63BA8F829A-095A

17 Faults Found:
00258 - Solenoid Valve 1 (N88)
36-00 - Open Circuit
00260 - Solenoid Valve 2 (N89)
36-00 - Open Circuit
00262 - Solenoid Valve 3 (N90)
36-00 - Open Circuit
00264 - Solenoid Valve 4 (N91)
36-00 - Open Circuit
00266 - Solenoid Valve 5 (N92)
36-00 - Open Circuit
00270 - Solenoid Valve 7 (N94)
36-00 - Open Circuit
00268 - Solenoid Valve 6 (N93)
36-10 - Open Circuit - Intermittent
00777 - Accelerator Position Sensor (G79)
27-00 - Implausible Signal
00660 - Kickdown Switch or Throttle Position Sensor
27-00 - Implausible Signal
00293 - Multi-function Switch (F125)
25-10 - Unknown Switch Condition - Intermittent
00281 - Vehicle Speed Sensor (G68)
03-00 - No Signal
00529 - Engine Speed Signal Missing
35-00 - -
00300 - Transmission Fluid Temp. Sensor (G93)
34-10 - No Elaboration Available - Intermittent
01236 - Shift Selector Locking Solenoid (N110)
31-00 - Open or Short to Ground
00545 - Engine-Transmission Electrical Connection
31-00 - Open or Short to Ground
00297 - Gearbox Speed Sensor (G38)
03-00 - No Signal
01314 - Engine Control Module
49-00 - No Communications

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1J0-907-37x-ABS.lbl
Part No: 1J0 907 379 P
Component: ABS 20 IE CAN 0001
Coding: 03504
Shop #: WSC 00066
VCID: 3E788E323A1468BAEF-4AE6

1 Fault Found:
18256 - Please check DTC Memory of Engine Controller
P1848 - 35-00 -

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 A
Component: 15 AIRBAG VW5 02 0004
Coding: 12597
Shop #: WSC 00066
VCID: 356A911E0F22ABE23E-4AE6

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx0-17.lbl
Part No: 1J0 920 900 M
Component: A4-KOMBIINSTR. VDO V59
Coding: 07242
Shop #: WSC 23329
VCID: 2C5CB47ADC68EA2A51-5120

Subsystem 1 - Part No: IMMO
Component: IDENTNR: VWZ7Z0Y2486871
IMMO-IDENTNR: VWZ7Z0Y2486871

1 Fault Found:
01314 - Engine Control Module
49-00 - No Communications

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00066
VCID: 70E4600A30C0CECA2D-5120

2 Faults Found:
01314 - Engine Control Module
49-00 - No Communications
01044 - Control Module Incorrectly Coded
35-00 - -

-------------------------------------------------------------------------------
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: 060826D22244F07AE7-4AE6

Subsystem 1 - Part No: 1J1959801C
Component: 61 Tõrsteuerger. FS0002r

Subsystem 2 - Part No: 1J1959802D
Component: 61 Tõrsteuerger. BF0002r

Subsystem 3 - Part No: 1J4959811C
Component: 61 Tõrsteuerger. HL0002r

Subsystem 4 - Part No: 1J4959812C
Component: 61 Tõrsteuerger. HR0002r

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1J0-035-18x-56.lbl
Part No: 1J0 035 180 D
Component: RADIO 3CP 0002
Coding: 02401
Shop #: WSC 00066
VCID: 2044504AA0A03E4AFD-4AE6

No fault code found.

End-------------------------(Elapsed Time: 06:02)--------------------------

Under instruments cluster there's a fault for no communication to the ECM. Fuse 37 should have voltage. I'd start there.

Ok I'll look into Fuse 37 then.

Why the low voltages on Fuse 34 and 32 then?
Thanks

No engine codes, that's something. Believe there is a coding with VCDS to tell it it's a manual.
Check the ASV is not sticking.

Now I went to plug in my Kermatdi q loader and it won’t read the ECU. Thought maybe it was the soft coding. Says ECU not found check cable and connections.

Could also be one of the fuses above the battery. I believe one of those could be culprit. Or a low battery.

Had a spare ECU from my other Jetta. My q loader communicated with it so installed the tune program for it successfully. Glow plug light is on. Attempted to start. It did but died in second. Now my key has to be programmed to that ECU I'd imagine. Tried the original ECU again. NO luck no glow plug lights. Think I should go with the spare ECU I have now? Maybe the original one is fried?
Fuses above battery are good by the way. Every fuse on that car is good.

BobnOH said:

No engine codes, that's something. Believe there is a coding with VCDS to tell it it's a manual.
Check the ASV is not sticking.

Click to expand...

Coding is correct. It is setup for a manual. Now for whatever reason on the original ECU it started up and running now.

Sounds like your original ecu is on its way out. By the way, you got the coding for a manual, is your TCM still plugged in? I'd unplug it, I heard having manual coding with the TCM connected still can cause goofy issues sometimes.

HelenaTDI said:

Had a spare ECU from my other Jetta. My q loader communicated with it so installed the tune program for it successfully. Glow plug light is on. Attempted to start. It did but died in second. Now my key has to be programmed to that ECU I'd imagine. Tried the original ECU again. NO luck no glow plug lights. Think I should go with the spare ECU I have now? Maybe the original one is fried?
Fuses above battery are good by the way. Every fuse on that car is good.

Click to expand...

You can do a voltage check on one of your sensors to confirm that your ECU is in fact dead. If you don’t see a 5v reference with KOEO, your ECU is no good




Sent from my iPhone using Tapatalk

Well after installing the original ECU and then I dumped in my flash from my q loader it now starts. Tried dozen times. Started every time. These are the codes I still get. Yes TCM is plugged in and has been since install. Like I said no issues with nearly 10K miles since the auto to 5spd swap.

Here is the most recent scan now.

Thursday,18,April,2019,17:48:05:25565
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 18.9.1.0
Data version: 20190114 DS296.0
www.Ross-Tech.com




Chassis Type: 9M - VW Jetta IV (1998 > 2014)
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
75 76

-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-012-AGR.clb
Part No: 038 906 012 BD
Component: 1,9l R4 EDC G500SG 2507
Coding: 00002
Shop #: WSC 00066
VCID: 53AECF86A19695D230-4B00

No fault code found.
Readiness: 0 0 1 0 1

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 01M-927-733.lbl
Part No: 01M 927 733 KA
Component: AG4 Getriebe 01M 4761
Coding: 00000
Shop #: WSC 00000
VCID: 79F25D2E63BA8F829A-095C

12 Faults Found:
00258 - Solenoid Valve 1 (N88)
36-00 - Open Circuit
00260 - Solenoid Valve 2 (N89)
36-00 - Open Circuit
00262 - Solenoid Valve 3 (N90)
36-00 - Open Circuit
00264 - Solenoid Valve 4 (N91)
36-00 - Open Circuit
00266 - Solenoid Valve 5 (N92)
36-00 - Open Circuit
00270 - Solenoid Valve 7 (N94)
36-00 - Open Circuit
00268 - Solenoid Valve 6 (N93)
36-10 - Open Circuit - Intermittent
00293 - Multi-function Switch (F125)
25-00 - Unknown Switch Condition
00281 - Vehicle Speed Sensor (G68)
03-00 - No Signal
00300 - Transmission Fluid Temp. Sensor (G93)
34-10 - No Elaboration Available - Intermittent
01236 - Shift Selector Locking Solenoid (N110)
31-00 - Open or Short to Ground
00297 - Gearbox Speed Sensor (G38)
03-00 - No Signal

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1J0-907-37x-ABS.lbl
Part No: 1J0 907 379 P
Component: ABS 20 IE CAN 0001
Coding: 03504
Shop #: WSC 00066
VCID: 3E788E323A1468BAEF-4AE6

1 Fault Found:
18256 - Please check DTC Memory of Engine Controller
P1848 - 35-00 -

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 A
Component: 15 AIRBAG VW5 02 0004
Coding: 12597
Shop #: WSC 00066
VCID: 356A911E0F22ABE23E-4AE6

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels:
Part No: 1J0 920 900 M
VCID: 2C5CB47ADC68EA2A51-5120


-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:
Part No: 6N0 909 901
VCID: 70E4600A30C0CECA2D-5120


-------------------------------------------------------------------------------
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: 060826D22244F07AE7-4AE6

Subsystem 1 - Part No: 1J1959801C
Component: 61 Tõrsteuerger. FS0002r

Subsystem 2 - Part No: 1J1959802D
Component: 61 Tõrsteuerger. BF0002r

Subsystem 3 - Part No: 1J4959811C
Component: 61 Tõrsteuerger. HL0002r

Subsystem 4 - Part No: 1J4959812C
Component: 61 Tõrsteuerger. HR0002r

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1J0-035-18x-56.lbl
Part No: 1J0 035 180 D
Component: RADIO 3CP 0002
Coding: 02401
Shop #: WSC 00066
VCID: 2044504AA0A03E4AFD-4AE6

No fault code found.

End-------------------------(Elapsed Time: 05:45)--------------------------

Disconnect your TCM, then go into your gateway, hit coding, then do it.

Not sure what that is going to gain me disconnecting the TCM? As I said it's coded correctly right now for the manual.

Some cars have issue with the abs if you leave the TCM connected and have the coding set for manual. Plus disconnecting it will get rid of all the extra faults.

Maybe dumping your stock flash on it fixed it. May have been an issue with the ROM on there causing a hangup. I'd keep the spare ECM handy just in case.