turbocharged798
Veteran Member
This TSB will fix the 04 BEW hard start issue. I was getting a "16705 - Engine Speed Sensor (G28): Implausible Signal" code almost all the time. I would clear it and it would come right back within a day or so. I was also getting a large cloud of smoke when starting when cold along with a rough running engine that would smooth out after a minuit or so. During a really wet period it got REALLY bad and threw a P0321 OBD code with a CEL. Tried replacing the crank sensor and battery, but neither did anything to fix it and both was a waste of time and money.
I got talking to oilhammer and he mentioned there was a TSB on it.Thanks to him, he sent me a TSB that VW released years ago to fix this issue. I'll write down exactly how to perform it and solve that issue for good.
Please note it states that this TSB only works with the newer software. If you are running original software from 2004, then it probably will not work but I can't say for sure since I did not try it. The TSB says its ONLY valid on vehicles with Software level below 6327 so make your own judgments there.
OK, lets get started. You will need:
1. Heat shrink butt crimps.(available at most hardware stores.) You want the RED 18-22AWG ones. DO NOT use the blue ones. They are too big and won't seal properly.
2.Friction electrical tape to rewrap the harness and make it look close to factory as possible. Most hardware stores have that as well.
3. Utility knife to cut open the harness.
4. Wire stripper/crimper tool. Proper one please, DO NOT use pliers.
5. Heat source to shrink the connectors.
6. A 000 979 009 repair wire. These are the same as the cluster terminals.
To start, disconnect the negative battery terminal, and remove the wipers and cowel. I assume you know how to do this. If you don't know how to do that, you probably shouldn't doing this TSB....
Locate the left most connector going to the ECU. It should be a 60 pin connector:
Unplug it, and pull it toward the drivers side of the car to make working on it easier. Cut the zip tie and remove the cover so it looks like so:
Now take your utility knife and start trimming back the cloth covering on the harness. BE CAREFUL!!!! DO NOT cut too deep and cut into the wires!!!
When you are done, it should look like this:
Locate this connection. There should be a black wire coming from pin 43 in the 60 pin connector. (T60/43) going to a black wire and white wire that goes to the G28 crank sensor:
Take your knife and slice the heat shrink down the middle, and then heat it up. It should peal right off the wire leaving the connection perfectly. Be careful you don't start ripping the wire insulation off...like I did....
Now separate the wires by pulling them apart. They are just pressed together:
Now, take some brake cleaner and clean the goo that is all over the copper wire. If you don't, it will not make a proper connection. If you have extra wire you can always just trim it back a bit and re strip the wire.
Put a butt connector between the black wire coming from T60/43 to the white wire coming from the G28 crank sensor. Crimp the connector and it should look like so:
Next, remove the secondary barrier from the 60 pin connector(forgot to take a pic of that) and remove the plug form spot 57 in the 60 pin connector:
And insert the 000 979 009 repair wire(or equivalent) into the hole. It only fits one way so make sure you check you are putting it in correctly. In case you are wondering, there is no seal there. The seal is built into the plug. You can see the rubber if you look down into the connector. Took me a while to figure that one out....
Tug on the wire to make sure its fully seated!
To be continued...
I got talking to oilhammer and he mentioned there was a TSB on it.Thanks to him, he sent me a TSB that VW released years ago to fix this issue. I'll write down exactly how to perform it and solve that issue for good.
Please note it states that this TSB only works with the newer software. If you are running original software from 2004, then it probably will not work but I can't say for sure since I did not try it. The TSB says its ONLY valid on vehicles with Software level below 6327 so make your own judgments there.
OK, lets get started. You will need:
1. Heat shrink butt crimps.(available at most hardware stores.) You want the RED 18-22AWG ones. DO NOT use the blue ones. They are too big and won't seal properly.
2.Friction electrical tape to rewrap the harness and make it look close to factory as possible. Most hardware stores have that as well.
3. Utility knife to cut open the harness.
4. Wire stripper/crimper tool. Proper one please, DO NOT use pliers.
5. Heat source to shrink the connectors.
6. A 000 979 009 repair wire. These are the same as the cluster terminals.
To start, disconnect the negative battery terminal, and remove the wipers and cowel. I assume you know how to do this. If you don't know how to do that, you probably shouldn't doing this TSB....
Locate the left most connector going to the ECU. It should be a 60 pin connector:
Unplug it, and pull it toward the drivers side of the car to make working on it easier. Cut the zip tie and remove the cover so it looks like so:
Now take your utility knife and start trimming back the cloth covering on the harness. BE CAREFUL!!!! DO NOT cut too deep and cut into the wires!!!
When you are done, it should look like this:
Locate this connection. There should be a black wire coming from pin 43 in the 60 pin connector. (T60/43) going to a black wire and white wire that goes to the G28 crank sensor:
Take your knife and slice the heat shrink down the middle, and then heat it up. It should peal right off the wire leaving the connection perfectly. Be careful you don't start ripping the wire insulation off...like I did....
Now separate the wires by pulling them apart. They are just pressed together:
Now, take some brake cleaner and clean the goo that is all over the copper wire. If you don't, it will not make a proper connection. If you have extra wire you can always just trim it back a bit and re strip the wire.
Put a butt connector between the black wire coming from T60/43 to the white wire coming from the G28 crank sensor. Crimp the connector and it should look like so:
Next, remove the secondary barrier from the 60 pin connector(forgot to take a pic of that) and remove the plug form spot 57 in the 60 pin connector:
And insert the 000 979 009 repair wire(or equivalent) into the hole. It only fits one way so make sure you check you are putting it in correctly. In case you are wondering, there is no seal there. The seal is built into the plug. You can see the rubber if you look down into the connector. Took me a while to figure that one out....
Tug on the wire to make sure its fully seated!
To be continued...
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