Newbie with a few questions.

First of all let me know if this is not the right place for this.

Hi, everyone.

I'm a new TDI owner and new to this forum.

I have a 2004 Beetle, diesel (of course), manual transmission. It has a few problems but I only paid $500 for it because someone hit a deer with it so I can afford to put some money in it. No serious damage but I replaced the windshield. I may replace the hood later if I can find one the right color at a salvage yard. There are a couple dents on the roof that I am going to live with.

I have a lot of questions but I am going to try to research as many as I can myself however I do have a couple issues that need attention. The CEL is on and when I put the scanner on three codes came up. I don't have the numbers in front of me now but I can get them.

Two of the codes said basically the same thing. Low turbocharger pressure. My limited preliminary research on YouTube suggests that it may be the diverter valve. I saw how to check for oil leakage through the electrical plug. I plan to do that soon but my lift isn't working and I am being slowed down by an injured foot but I can drive it up onto ramps. I saw the valve for sale on eBay for about $35. I would rather buy local to be sure I am getting the right part but the local part stores can't find a listing for it. Is there a different name I should be asking for? Any advice would be appreciated.

The other code that popped up was for low coolant temperature. There is no gauge on the dash but the heater works good so I'm thinking it's the sensor. The sensors that I'm seeing have a D shaped plug with 4 pins. I can't find a plug like that on my car. When I look at what I'm pretty sure is the thermostat housing I see three separate sensors with one wire each. Is the sensor somewhere I'm not looking? Since this is the first year for the PD motor could this be an early version?

Thanks in advance.

I can't speak to the '04's motor, but for scanning, you really want VCDS vs.
a generic OBD. Then you can search that number on bing: ross-tech <number>
Best way to search this site is similar: tdiclub issue-at-hand on your
search engine of choice. I generally get better results from Bing.
And ~ Welcome!

vintage red matthew said:

... someone hit a deer with it ... There are a couple dents on the roof that I am going to live with...

Click to expand...

I'll bet you that the deer didn't do those.

Cheers,

PH

Not sure what you mean by "diverter valve". The fault codes would definitely be helpful...

Powder Hound said:

I'll bet you that the deer didn't do those.
Cheers,
PH

Click to expand...

Yes, it did. A dent near the top of the windshield, which was badly shattered. Luckily the lip where the windshield sits was not damaged. Also the deer took off the radio antenna on its was over and left a dent there too.

1854sailor said:

Not sure what you mean by "diverter valve". The fault codes would definitely be helpful...

Click to expand...

Diverter valve was what they called it on a couple YouTube videos that I watched. I'm thinking this might also be called the blow off valve or pop off valve. But I could be wrong about that. As I said I'm a beginner to diesel turbos.

Fault codes were:

P0299 turbocharger/supercharger underboost.

P0128 coolant thermostat, coolant temperature below thermostat regulating temperature

P2564 turbocharger boost control position sensor A circuit low.

Thanks again.

Your car does not have a "blow off" or "pop off" valve. Boost is controlled by the turbo's VNT (variable vane) system. The VNT actuator on the 1.9L PD motors has a position sensor that can be problematic. Check out This thread. It could be something as simple as a loose connection.

I knew you guys would point me in the right direction. Glad I came here.

I had no idea that it was a variable vane setup.

I will get under and inspect those wires and report back.

What about the low coolant temperature code? Where is the coolant temp sensor? I still haven't found a D shaped, 4 pin plug. Where should I be looking?

Right (driver's) side of the engine, under the tandem pump.

vintage red matthew said:

...Where is the coolant temp sensor? I still haven't found a D shaped, 4 pin plug. Where should I be looking?

Click to expand...

OK, I'm just starting to learn this stuff. Please bear with me if I ask a lot of stupid questions.

I know I should use a VCDS scanner. I may be mistaken but did I hear that O'Reiliy's will scan it for me if I take it there? If not do I need to take it to a shop that has that?

The thread that was linked to said it might be a problem with broken wiring. I put it on stands and looked and the wires and hoses looked OK.

I also heard that the vanes can get stuck and you can check that by putting vacuum to the actuator. My Mighty Vac gave out so I need to get a new one. How much should the actuator move?

Do I have a BEW motor? I found someone selling a rebuilt turbo for $325 exchange. That seems reasonable to me if, of course that is what I need.

While I was under the car I saw that it needs both axle assemblies. I took them out yesterday and plan to put the new ones in tonight. Does anyone know offhand what the torque rating is for the inner CV joint Allen bolts and spindle nuts? If not I can look it up myself. Should I use Locktight or anti seize?

I plan to keep this car for a long time. I guess I should bite the bullet and get a Bentley manual.

Assuming the BEW NB is the same setup as an ALH Jetta, I think the torque spec is 22 ft-lbs.

I put blue locktight on mine, especially since I've had problems with the allen bolts backing out. The triple square bolts I have not had any issues with.

There are a lot of threads addressing your underboost issue, as well as limp mode in general. So I wouldn't go buy a turbo just yet.

Powder Hound said:

I'll bet you that the deer didn't do those.
Cheers,
PH

Click to expand...

I hit a deer with my Jetta. What makes that so improbable?

Have you checked all the boost/intake pipes to make sure they are all firmly and correctly connected? Impact of a deer may have knocked something loose by chance.

Lightflyer1 said:

Have you checked all the boost/intake pipes to make sure they are all firmly and correctly connected? Impact of a deer may have knocked something loose by chance.

Click to expand...

Good point. The deer hit the passenger side near the intercooler. All the pipes that I can easily see look good but I'll look closer at all of them.

Believe me. I am not going to buy a new turbo unless I have a pretty good idea that's the problem. I was just looking out of curiosity and that seemed like a good price if that turns out to be what my problem is.

When I had a diesel Rabbit, back in the day a Bentley service manual was the bible. This car is a completely different animal. As I said I'm learning. Do I need to get a VAG-COM? They seem pretty cool but I don't how much I would use it after I've sorted my current problems. I'm not that great with computers either. Would it be more cost efficient to pay someone who knew what they are doing to diagnose it for me?

You are lucky, maybe. I am taking my father back to Wichita from Austin Texas. This will happen the 10th and I could bring my VCDS (old name is Vag-Com) with me and scan your car that evening if you aren't busy then. I would be leaving early on the 11th to return so that would be the only window of opportunity. Reply to let me know if you want to do this. Should only take minutes to do. Simple short trip from Central up Ridge road to there about 15 miles. I would like to leave here about 6am so as to arrive there early evening.

Lightflyer1 said:

You are lucky, maybe. I am taking my father back to Wichita from Austin Texas. This will happen the 10th and I could bring my VCDS (old name is Vag-Com) with me and scan your car that evening if you aren't busy then. I would be leaving early on the 11th to return so that would be the only window of opportunity. Reply to let me know if you want to do this. Should only take minutes to do. Simple short trip from Central up Ridge road to there about 15 miles. I would like to leave here about 6am so as to arrive there early evening.

Click to expand...

That's fantastic. It should work out fine. The 10th is on Saturday, as I'm sure you know. I work in Wichita until 1PM. I could come to you. I will be free all evening. Just let me know where and when.

I already know I am going to like this site.

They live around the Central and Ridge Road area. Send me a message here with your phone number and I can keep you informed as to my progress as I get close.

Here is your scan.

Saturday,10,August,2019,07:02:12:44380
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x86
VCDS Version: 19.6.1.0
Data version: 20190529 DS308.0
www.Ross-Tech.com


VIN: 3VWCR31C44M415576 License Plate: YYYYYY
Mileage: 296490km-184230mi Repair Order: yyyyy



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1C (1C - VW New Beetle (1998 > 2010))
Scan: 01 02 03 08 15 17 19 25 29 35 37 39 46 54 56 65 75

VIN: 3VWCR31C44M415576 Mileage: 296490km-184230miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-016-BEW.lbl
Part No SW: 038 997 016 S HW: 028 101 114 7
Component: R4 1,9L EDC G000SG 0283
Revision: 12345678 Serial number: VWZ5Z0D0078243
Coding: 0150031
Shop #: WSC 24339 444 85547
VCID: 2E58CC51BABA193F3B-5178

4 Faults Found:
18996 - Turbocharger Boost Control Position Sensor Circuit
P2564 - 000 - Signal too Low
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Lambda: 0.0 %
Absolute Pres.: 183.6 mbar
Absolute Pres.: 938.4 mbar

19463 - Camshaft Position Sensor (G40)
P3007 - 000 - No Signal - Intermittent
Freeze Frame:
RPM: 2142 /min
Torque: 94.0 Nm
Speed: 94.0 km/h
Load: 0.0 %
Voltage: 14.44 V
Bin. Bits: 01101000
Idle Stabilization: -2.0°KW
(no units): 48.0

16512 - Coolant Thermostat Valve (N214)
P0128 - 000 - Temperature below Control Range
Freeze Frame:
RPM: 1533 /min
Torque: 88.0 Nm
Speed: 24.0 km/h
Temperature: 63.9°C
Fuel Consump.: 2.80 l/h
Temperature: 36.0°C
Temperature: 36.0°C
Absolute Pres.: 969.0 mbar

16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
RPM: 2268 /min
Torque: 220.0 Nm
Speed: 101.0 km/h
Load: 76.1 %
Voltage: 13.83 V
Bin. Bits: 00101100
Absolute Pres.: 2029.8 mbar
Absolute Pres.: 1581.0 mbar

Readiness: 1 3 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ESP-F.lbl
Part No: 1C0 907 379 M
Component: ESP FRONT MK60 0102
Coding: 0019458
Shop #: WSC 00028 000 00000
VCID: 346CDE39549633EF4D-5178

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1T0-909-605.lbl
Part No: 6Q0 909 605 AG
Component: 01 AIRBAG VW71 0710
Coding: 0012337
Shop #: WSC 00066 000 00000
VCID: 7CFC36193C463BAFC5-5178

Subsystem 1 - Part No: 1C0 959 339
Component: BF-Gewichtsens. 004 0004

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1C0-920-x4x.lbl
Part No: 1C0 920 951 A
Component: KOMBI+WEGFAHRS. M73 V02
Coding: 11232
Shop #: WSC 00000
VCID: 1F4621959D1080B780-4B32
3VWCR31C44M415576 VWZ5Z0D0078243

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN V022
Coding: 00006
Shop #: WSC 00028
VCID: 70E41229300E4FCF69-4B18

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 G
Component: 2K Komfortgerát HLO 0004
Coding: 00064
Shop #: WSC 00028
VCID: 3B7EF50529C8FC978C-4B32

Subsystem 1 - Part No: 1C2959802A
Component: 2K Tõrsteuer.FS KLO 0202

Subsystem 2 - Part No: 1C2959801A
Component: 2K Tõrsteuer.BF KLO 0202

1 Fault Found:
01044 - Control Module Incorrectly Coded
35-00 - -

End-------------------------(Elapsed Time: 04:00)--------------------------