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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 3rd, 2017, 13:58   #1
zortmo
Member
 
Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
Default 2006 Jetta TDI - 30 DTC errors - Where to start?

I have new battery, checked grounds under battery box, alternator checks good, fuses inside and under hood check good.
We got an intermittent battery light on a recent trip so I scanned and the only thing that looked related was the P1503. A couple of weeks later the car wouldn't go into gear at a traffic light and the dash warning lights were lit up like a christmas tree. Scanned again to find 30+ errors. With all the error codes the car still starts fine, alternator charging 14.4. It goes into gear but I haven't driven since towing home.
The way my wife described the breakdown I thought bad mechatronic but it appears there's low voltage everywhere. I have a Bentlely for my other tdi's but not for this one. I suppose it's time to start tracing wires. Anybody seen this before?
Thanks, Mike
Date: 2017-12-03 15:01
VIN:
Car: Volkswagen Jetta
Year: 2006
Body type: Saloon
Mileage: 323290 KM
---------------------------------------------------------------
00 Steering Angle Sender
---------------------------------------------------------------
01 Engine
System description: R4 1,9L EDC G000DG
Software number: 03G906016AC
Software version: 7551
Hardware number: 0281012239
Serial number: VWZ7Z0F3432623
Coding: 0050078
Trouble codes:
P161A - Glow plug cylinder 1 Open circuit
static
P161B - Glow plug cylinder 2 Open circuit
static
P0401 - Exhaust Gas Recirc.Flow Insufficient Detected
Intermittent
P1503 - Load signal terminal DF of Generator Implausible signal
static
P2015 - Intake Manifold Runner Position Sensor/Switch Circuit Range/Performance
Intermittent
P0102 - Mass or Volume Air Flow Circ. Low Input
static
---------------------------------------------------------------
02 Transmission
System description: GSG DSG 070
Software number: 02E300043
Software version: 1126
Hardware number: 02E927770AE
Hardware version: C30
Serial number: 00000601100069
Coding: 0000020
Trouble codes:
00446 - Function limitation due to insufficient voltage
Intermittent
P1850 - Databus drivetrain Missing Message from Engine CM
Intermittent
---------------------------------------------------------------
03 Brakes
System description: ESP FRONT MK60
Software number: 1K0907379AA
Software version: 0102
Hardware number: 1K0907379AA
Coding: 0021122
Trouble codes:
01314 - Engine control module (ECM) Please read DTC
Intermittent
00668 - Vehicle voltage terminal 30 Lower limit not reached
Intermittent
01314 - Engine control module (ECM) No signal/communication
Intermittent
---------------------------------------------------------------
04 Steering Angle Sender
---------------------------------------------------------------
08 Air Conditioning
System description: Climatic PQ35 090
Software number: 1K0820047EC
Software version: 0505
Trouble codes:
00532 - Supply voltage Lower limit not reached
Intermittent
---------------------------------------------------------------
09 Central Electrics
System description: Bordnetz-SG H37
Software number: 3C0937049D
Software version: 1002
Hardware number: 3C0937049D
Hardware version: 063
Serial number: 00000000279098
Long coding: 14018E234004150000140000001400000008730B5C
Subsystems:
System description: Wischer VW350 013
Software number: 1K1955119C
Software version: 0402
Coding: 0063445
Trouble codes:
00446 - Function limitation due to insufficient voltage Lower limit not reached
Intermittent
---------------------------------------------------------------
0F Radio Tuner Digital
System description: SDAR XM H03
Software number: 8E0035593E
Software version: 0080
Hardware number: 8E0035593E *
Serial number: AUZ4Z7F7044106
Trouble codes:
00532 - Supply voltage Lower limit not reached
Intermittent
00446 - Function limitation due to insufficient voltage Lower limit not reached
Intermittent
02635 - Tuner not enabled/activated
static
---------------------------------------------------------------
15 Airbag
System description: 39 AIRBAG VW8R 032
Software number: 1K0909605P
Software version: 7900
Hardware number: 1K0909605P
Hardware version: 003
Serial number: 0038FD04JDJ8
Coding: 0013113
Subsystems:
System description: BF-Gewichtsens. 006
Software number: 1K0959339E
Software version: 0005
Trouble codes:
00532 - Supply voltage Lower limit not reached
Intermittent
---------------------------------------------------------------
16 Steering Column Electronics
System description: J0527 034
Software number: 1K0953549AH
Software version: 0070
Hardware number: 1K0953549AH
Coding: 0010021
Trouble codes:
00532 - Supply voltage Lower limit not reached
Intermittent
---------------------------------------------------------------
17 Dash Board
System description: KOMBIINSTRUMENT 3HL
Software number: 1K0920953D
Software version: 4312
Coding: 0023206
Trouble codes:
01314 - Engine control module (ECM) No signal/communication
Intermittent
---------------------------------------------------------------
19 Gateway
System description: Gateway H10
Software number: 1K0907530F
Software version: 0120
Hardware number: 1K0907951
Serial number: 28001061080726
Long coding: 3F3F0B60071002
Trouble codes:
01314 - Engine control module (ECM) No signal/communication
Intermittent
---------------------------------------------------------------
25 Immobilizer
System description: IMMO 3HL
Software number: 1K0920953D
Software version: 4312
Trouble codes:
No trouble codes found
---------------------------------------------------------------
42 Door Electronics Driver Side
System description: Tuer-SG 024
Software number: 1K0959701K
Software version: 2377
Coding: 0001269
Trouble codes:
01811 - Supply voltage for door control module, driver side Lower limit not reached
Intermittent
01552 - Driver door central locking LOCK motor Electrical malfunction in circuit
static
00928 - Lock unit for central locking Driver side Implausible signal
static
---------------------------------------------------------------
44 Steering Assistance
System description: EPS_ZFLS Kl.5 D04
Software number: 1K1909144J
Software version: 1606
Trouble codes:
00446 - Function limitation due to insufficient voltage Lower limit not reached
Intermittent
01314 - Engine control module (ECM) No signal/communication
Intermittent
00778 - Steering angle sensor
static
---------------------------------------------------------------
46 Central Module Comfort System
System description: KSG
Software number: 1K0959433AF
Software version: 0401
Long coding: 137803281B09058F880F048051A0
Subsystems:
System description: Sounder n.mounted
System description: NGS n.mounted
System description: IRUE n.mounted
Trouble codes:
00668 - Vehicle voltage terminal 30 Lower limit not reached
Intermittent
---------------------------------------------------------------
52 Door Electronics Passenger Side
System description: Tuer-SG 024
Software number: 1K0959702K
Software version: 2377
Coding: 0001269
Trouble codes:
01812 - Supply voltage for door control module, frt. pass. side Lower limit not reached
Intermittent
---------------------------------------------------------------
56 Radio
System description: Radio DE2 011
Software number: 1K0035180C
Software version: 0015
Hardware number: 1K0035180C
Hardware version: 000
Serial number: VWZ4Z7F2110489
Coding: 0010400
Trouble codes:
00003 - Control module Faulty
static
---------------------------------------------------------------
62 Door Electronics Rear Left
System description: Tuer-SG 021
Software number: 1K0959703D
Software version: 2434
Coding: 0000144
Trouble codes:
01813 - Supply voltage for door control module, left rear Lower limit not reached
Intermittent
---------------------------------------------------------------
72 Door Electronics Rear Right
System description: Tuer-SG 021
Software number: 1K0959704D
Software version: 2434
Coding: 0000144
Trouble codes:
01814 - Supply voltage for door control module, right rear Lower limit not reached
Intermittent
00935 - Right rear window lift motor no or incorrect basic setting/adaptation
Intermittent
---------------------------------------------------------------
7D Auxiliary Heater
System description: PTC-Element
Software number: 1K0963235E
Software version: 0404
Hardware number: 1K0963235E
Trouble codes:
00361 - Heater element for aux. heater Faulty
static
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Old December 3rd, 2017, 15:07   #2
Tdijarhead
Veteran Member
Default

Your failing battery got the best of your cars ecu. Clear the codes and see what comes back. This kind of thing happens all the time when a battery goes on permanent vacation.
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Old December 4th, 2017, 06:12   #3
zortmo
Member
 
Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
Default

Thanks jarhead! You were right. I'm back down to 4 or 5 errors.

I drove the car and it seems to be shifting ok, BUT I still have the battery warning light displaying (this is where the original problem began). On the recent trip it would come on and go off for around 10 minutes. Now it's on most of the time. Here's my latest scan. BTW, the battery always tested good, and alternator as well. It's charging 14.4 now. I replaced battery because it's my wife's daily driver and I thought maybe something weird was causing the battery light.

Date: 2017-12-04 07:48

VIN: 3VWST71K66M788911
Car: Volkswagen Jetta
Year: 2006
Body type: Saloon
Mileage: 323290 KM

---------------------------------------------------------------
00 Steering Angle Sender

---------------------------------------------------------------
01 Engine

System description: R4 1,9L EDC G000DG
Software number: 03G906016AC
Software version: 7551
Hardware number: 0281012239
Serial number: VWZ7Z0F3432623
Coding: 0050078

Trouble codes:
P161A - Glow plug cylinder 1 Open circuit
static
P161B - Glow plug cylinder 2 Open circuit
static
P0102 - Mass or Volume Air Flow Circ. Low Input
static


---------------------------------------------------------------
02 Transmission

System description: GSG DSG 070
Software number: 02E300043
Software version: 1126
Hardware number: 02E927770AE
Hardware version: C30
Serial number: 00000601100069
Coding: 0000020

Trouble codes:
No trouble codes found

---------------------------------------------------------------
03 Brakes

System description: ESP FRONT MK60
Software number: 1K0907379AA
Software version: 0102
Hardware number: 1K0907379AA
Coding: 0021122

Trouble codes:
No trouble codes found

---------------------------------------------------------------
04 Steering Angle Sender

---------------------------------------------------------------
08 Air Conditioning

System description: Climatic PQ35 090
Software number: 1K0820047EC
Software version: 0505

Trouble codes:
No trouble codes found

---------------------------------------------------------------
09 Central Electrics

System description: Bordnetz-SG H37
Software number: 3C0937049D
Software version: 1002
Hardware number: 3C0937049D
Hardware version: 063
Serial number: 00000000279098
Long coding: 14018E234004150000140000001400000008730B5C

Subsystems:
System description: Wischer VW350 013
Software number: 1K1955119C
Software version: 0402
Coding: 0063445

Trouble codes:
No trouble codes found

---------------------------------------------------------------
0F Radio Tuner Digital

System description: SDAR XM H03
Software number: 8E0035593E
Software version: 0080
Hardware number: 8E0035593E *
Serial number: AUZ4Z7F7044106

Trouble codes:
02635 - Tuner not enabled/activated
static


---------------------------------------------------------------
15 Airbag

System description: 39 AIRBAG VW8R 032
Software number: 1K0909605P
Software version: 7900
Hardware number: 1K0909605P
Hardware version: 003
Serial number: 0038FD04JDJ8
Coding: 0013113

Subsystems:
System description: BF-Gewichtsens. 006
Software number: 1K0959339E
Software version: 0005

Trouble codes:
No trouble codes found

---------------------------------------------------------------
16 Steering Column Electronics

System description: J0527 034
Software number: 1K0953549AH
Software version: 0070
Hardware number: 1K0953549AH
Coding: 0010021

Trouble codes:
No trouble codes found

---------------------------------------------------------------
17 Dash Board

System description: KOMBIINSTRUMENT 3HL
Software number: 1K0920953D
Software version: 4312
Coding: 0023206

Trouble codes:
No trouble codes found

---------------------------------------------------------------
19 Gateway

System description: Gateway H10
Software number: 1K0907530F
Software version: 0120
Hardware number: 1K0907951
Serial number: 28001061080726
Long coding: 3F3F0B60071002

Trouble codes:
No trouble codes found

---------------------------------------------------------------
25 Immobilizer

System description: IMMO 3HL
Software number: 1K0920953D
Software version: 4312

Trouble codes:
No trouble codes found

---------------------------------------------------------------
42 Door Electronics Driver Side

System description: Tuer-SG 024
Software number: 1K0959701K
Software version: 2377
Coding: 0001269

Trouble codes:
No trouble codes found

---------------------------------------------------------------
44 Steering Assistance

System description: EPS_ZFLS Kl.5 D04
Software number: 1K1909144J
Software version: 1606

Trouble codes:
00778 - Steering angle sensor
static


---------------------------------------------------------------
46 Central Module Comfort System

System description: KSG
Software number: 1K0959433AF
Software version: 0401
Long coding: 137803281B09058F880F048051A0

Subsystems:
System description: Sounder n.mounted

System description: NGS n.mounted

System description: IRUE n.mounted

Trouble codes:
No trouble codes found

---------------------------------------------------------------
52 Door Electronics Passenger Side

System description: Tuer-SG 024
Software number: 1K0959702K
Software version: 2377
Coding: 0001269

Trouble codes:
No trouble codes found

---------------------------------------------------------------
56 Radio

System description: Radio DE2 011
Software number: 1K0035180C
Software version: 0015
Hardware number: 1K0035180C
Hardware version: 000
Serial number: VWZ4Z7F2110489
Coding: 0010400

Trouble codes:
00003 - Control module Faulty
static


---------------------------------------------------------------
62 Door Electronics Rear Left

System description: Tuer-SG 021
Software number: 1K0959703D
Software version: 2434
Coding: 0000144

Trouble codes:
No trouble codes found

---------------------------------------------------------------
72 Door Electronics Rear Right

System description: Tuer-SG 021
Software number: 1K0959704D
Software version: 2434
Coding: 0000144

Trouble codes:
No trouble codes found

---------------------------------------------------------------
7D Auxiliary Heater

System description: PTC-Element
Software number: 1K0963235E
Software version: 0404
Hardware number: 1K0963235E

Trouble codes:
00361 - Heater element for aux. heater Faulty
static
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Old December 4th, 2017, 10:17   #4
DanG144
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Join Date: Aug 2007
Location: Chapin, South Carolina, USA
Default

I had a friend who had a bad connector onto his alternator, this caused similar problems. We replaced the connector and all was well.

The ECU is seeing voltage varying too much. This can be caused by control signal issues or power wire issues, or bad diodes in your alternator.


Check for AC out of your alternator as well - excess ripple - I think that some local auto parts places will do this for you.


Clean both ends of the alternator power cable. Ensure the 200 or 150 amp fuse for the alternator is not discolored by heat.

I would also clean (not just look at but unhook and clean) the grounds under the battery tray (the ones that ground body and engine to battery) and the grounds in the windshield wiper plenum under the windshield, and the main engine ground.

Chafed wiring in the harness above the starter is also a possibility, but I would probably do these checks in the order listed.
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Old December 4th, 2017, 10:19   #5
DanG144
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Join Date: Aug 2007
Location: Chapin, South Carolina, USA
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Since the ECU uses the load signal from the alternator as an input to the transmission control, if the load signal gets too erratic, the system can cause the transmission to quit working, just due to alternator/main power bus issues.
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Old December 4th, 2017, 16:56   #6
zortmo
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Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
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Thanks for the reply Dan. I can do everything but the ac ripple. I'm afraid to drive it to the local Autozone. I'll try to think of a solution.
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Old December 6th, 2017, 07:47   #7
zortmo
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Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
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I have an old analog oscilloscope that I decided to risk blowing up and hooked it up. It seemed to do fine. It doesn't give me actual values of peaks but I compared the trace on the TDI to my toyota truck. In comparison it looked to be "hunting around" and it had some random but distinct negative spikes. I decided to order a new Bosch unit. Its due later this week.

I'm finishing up cleaning grounds and main cable from alternator to battery. There's no darkness on the 200amp fuse or any signs of being hot, however one side of one of the front 40amp fuses has been hot. One blade is discolored and the plastic on the fuse box base is slightly deformed. I cleaned it and reinstalled.

I'll report back after installing alternator.

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Old December 7th, 2017, 15:17   #8
DanG144
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Join Date: Aug 2007
Location: Chapin, South Carolina, USA
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I would think that an AC voltmeter would work for you. In general terms high ripple means problems. Sometimes I hear 50 mv AC is the upper limit, sometimes 100 mv ac. My car is in the body shop (totaled by deer strike), or I would check it for you.

The value of ripple will be higher at the alternator than at the battery. You see folks say to check it one place or the other - as long as you know what is normal you can check it either place.

If the AC voltage is greater than 100 mV at the battery, I would suspect an issue, based on a general look around.

A word of warning, meter quality does differ. When making expensive decisions, especially with slightly unusual measurements, do some sanity checks (by internet, or yourself); the first meter I grabbed - a very cheap ALLSUN or ALLOSUN EM380 that I keep under the truck seat - showed 29.6 vac on my Dodge truck, and 29.0 VAC on my wife's Toyota at the battery.

So I checked again with my Fluke, and it showed 10 mv ac on my Dodge, and 25 mv ac on the Toyota.

The general design of the systems is all the same, so I would expect that the ripple values are fairly consistent. Since my Dodge has two very large batteries, I was not surprised to see a lower ripple value. The smaller the battery, the larger ripple I would expect, as (generally speaking) the internal resistance would be higher - developing more voltage from a given AC current.

I have vague memories of a very contentious thread on this topic on this site in past years. While I welcome feedback and especially experience reports, don't anyone expect an argument from me.

Zortmo, it would be nice to hear any AC readings from across your battery terminals, from the old alternator and the new.

Zortmo, as part of your charging system general health checks, you can also check the voltage drops across your very large, high current flow cables. Again generally speaking if you have more than about a 0.2v drop across a connection, it would be suspect. If you have any connections that get so hot you cannot touch them, again that is suspect.

Many older cables will get corrosion inside the lugs, where it is invisible, causing poor connections and high voltage drops. There are some good threads here about aftermarket power cable sources.
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Old December 8th, 2017, 07:39   #9
zortmo
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Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
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Thanks Dan. I don't have a Fluke which is a true RMS meter. My cheaper meter can only measure peaks. So it always reads around 30vac. I primarily tested ac ripple between B+ on the alternator and negative battery post, but I also looked between B+ and alternator body. I'll have a look across the battery terminals before I change it for the new one. Unfortunately I don't have a true rms meter so no actual ripple value.
I'll also look at voltage drop across the fat cables. Like I said, I only see one fuse in the under hood fuse box that has been hot. I don't have a wiring diagram to see what circuit it's a part of (the owners manual is not clear). Maybe after getting through Christmas I can order a Bentley for the 06.
My fuse box pic
Thanks again for your help.
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Old December 9th, 2017, 06:22   #10
DanG144
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My Bentley manual has some fuse data, but it is also hard to use for the "low" fuse panel model that is like your picture. It put in another numbered sketch of the "high" panel rather than the proper low panel sketch.

However, if i use the same numbering scheme on the low panel as was used on the high, that is fuse #SB30, a 40 amp fuse that is part of the power to the Vehicle electrical control module J519.

Assuming it is fuse SB30, and then going to wiring diagram 52/11, then following the numbering to diagram 52/12, it shows that fuse to be the main power feed to the J59 LOAD REDUCTION RELAY, which powers fuses SC40, 41, 42, 46, 49. These are the loads that are shut off during engine starting by the LLR. The largest of these is the SC40 which powers the air conditioner control module, J301.

I have no experience doing this on your type of fuse panel, but on others (mark IV), when it starts to get hot, you need to disassemble the base and clean the connections, perhaps doing a bit of re-bending or even tinning the contact points with solder.

However, I don't think this is causing your main issue.
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Old December 9th, 2017, 06:30   #11
DanG144
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Are you seeing any idle speed changes on your car when it is acting up? If voltage drops to less than 12.7 it is supposed to increase idle speed. If it drops to less than 12.2 volts it shuts off a list of loads (including the AC), then even more at 11.8 volts.
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Old December 9th, 2017, 14:07   #12
zortmo
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Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
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Thanks for the info Dan. I need the bentley.

My wife says no on the idle going up although she says it was kinda frantic as she was stuck in a busy intersection.

It sounds like one of the load circuits is seeing high resistance and getting hot. I have a similar situation with my a4.

I noticed at idle I see no battery light. At about 2k rpms it comes on. So I measured voltage at idle, and at 2k. At idle it's 14.4vdc; at 2k it's 12.1vdc. I wonder what the voltage is doing at higher revs at interstate speeds? Maybe voltage regulator is going away after all?

Btw, voltage drop across alternator cable is .046. It's .081 from battery minus to alternator housing. Should be good to go.

Thanks, Mike
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Old December 10th, 2017, 10:21   #13
DanG144
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This is still on the old alternator?

Are you near the coast? History of corrosion?

Do you have VCDS? There are some alternator load control fields.
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Old December 11th, 2017, 04:05   #14
zortmo
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Join Date: Aug 2009
Location: Ga
TDI(s): 99, 01, 06
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Yes still old alternator. New one should be here today.
Not near coast. Northeast GA.
I have VCDS for my 99 and 01. I have OBDeleven for the 06. It allows me to monitor live data but a little harder to find. I have to know the correct field. Do you mean this? http://wiki.ross-tech.com/wiki/index.php/17911/P1503

Last edited by zortmo; December 11th, 2017 at 06:39.
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Old December 13th, 2017, 05:13   #15
DanG144
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Look at fields 12,3 for voltage, 16,1 for alternator load. 16,4 for voltage again.

The Ross-tech link also sends you to field 16,1 for alternator load signal.

I thought the alternator load showed up somewhere else, but I could not find it. It is reported to the transmission for automatics.

Check field 16,2 for the code number as indicated below. (This may not work on all BRMs).

016,0,Auxiliary Heating

016,1,Generator Load,,Specification: 5.0...95.0 %

016,2,Auxiliary Heating,Shut-Off Conditions,See Label File

; xxxxxxx1 = Coolant Temparature above 80.0 ∞C

; xxxxxx1x = Generator Malfunction

; xxxxx1xx = Battery Voltage too Low

; xxxx1xxx = Engine Speed too Low

; xxx1xxxx = Start Delay active

; xx1xxxxx = System Malfunction [Coolant Temp. Sensor (G62) OR Intake Air Temp. Sensor (G72) FAULTY]

; 1xxxxxxx = Ambient Temperature above 5.0 ∞C

016,3,Heating Element,Activation,1x - Relay for Coolant Preheat. (High Output - J360) activated\nx1 - Relay for Coolant Preheat. (Low Output - J359) activated

016,4,Supply Voltage,(Terminal 30),Specification: 13.0...15.0 V
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