Engine/Electrical Issues P0322 fault

2005 Mk5 Jetta, 5M, ~170,000 miles. Car has been extremely reliable to this point. Driving on the highway last week, without warning the car stalls, glow plug light flashing, low oil pressure indicator, emissions workshop and other stuff. Oil was 1.5 qts low, due for oil change I hadn't gotten to yet. Car had never stalled before. Oil topped up, problem remains. My battery was going (the original in fact), which I replaced with an OEM from the dealer. While installing the battery I took the opportunity to remove airbox and battery box and clean and reconnect the 4-5 grounds accessible there. I also removed the split loom and visually inspected the harness wires from the driver headlight to the engine where it becomes inaccessible. No evidence of chaffed or damaged wires at all. I checked and re-seated all the fuses and modules, none seemed loose. Put back together and the behavior thru several days is roughly the same each time. After sitting for awhile or overnight car starts and runs normally, but within 5 minutes or so will stall and produce the flashing glowplug, low oil pressure indicator, emissions workshop, sometimes the tach works sometimes it doesn't. After the stall, car takes longer to start and makes a different sound while starting and doesn't rev above ~3000.

VagCom shows:

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: Malfunction 0010
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: OK 0000
1C-Position Sensing -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: Malfunction 0010
62-Door, Rear Left -- Status: Malfunction 0010
72-Door, Rear Right -- Status: Malfunction 0010
7D-Aux. Heat -- Status: OK 0000

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Address 01: Engine Labels: 038-906-016-BEW.lbl
Part No SW: 03G 906 016 AB HW: 028 101 223 8
Component: RC s01f EDC G000SG 7550
Revision: --H01--- Serial number: xxx
Coding: 0050071
Shop #: WSC 66565 257 00032
VCID: 63C5135BA24E991

1 Fault Found:
000802 - Engine Speed Sensor (G28)
P0322 - 000 - No Signal - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 0
Fault Frequency: 2
Mileage: 274224 km
Time Indication: 0
Date: 2000.00.00
Time: 04:58:34

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
Load: 90.2 %
Voltage: 11.17 V
Bin. Bits: 00001100
Idle Stabilization: 0.0°KW
RPM: 126 /min

Readiness: 0 0 0 0 1

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Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No: 1K0 907 379 K
Component: ESP FRONT MK60 0104
Coding: 0021122
Shop #: WSC 00066 000 00000
VCID: 3A7B8E3F7544B89

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory

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Address 08: Auto HVAC Labels: 1K0-907-044.lbl
Part No: 1K0 907 044 AG
Component: ClimatronicPQ35 066 0505
Shop #: WSC 00000 000 00000
VCID: 6CD778674F90D69

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory

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Address 09: Cent. Elect. Labels: 3C0-937-049-23-H.lbl
Part No SW: 1K0 937 049 C HW: 1K0 937 049 C*
Component: Bordnetz-SG H34 0803
Revision: 00H34000 Serial number: 00000000063785
Coding: F4098E02400418000014000000140000002077035C
Shop #: WSC 00000 000 00000
VCID: 2F6DAF6BBE066D1

Subsystem 1 - Part No: 1K1 955 119 B Labels: 1KX-955-119.CLB
Component: Wischer VW350 012 0401
Coding: 00065493
Shop #: WSC 00000

Subsystem 2 - Part No: 1K0 955 559 M Labels: 1K0-955-559-AF.CLB
Component: RegenLichtSens 005 0605
Coding: 00217125
Shop #: WSC 00000

1 Fault Found:
02385 - Rain / Light Recognition Sensor Function Restricted due to Under-Voltage
002 - Lower Limit Exceeded - Intermittent

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Address 15: Airbags Labels: 1K0-909-605.lbl
Part No SW: 1K0 909 605 E HW: 1K0 909 605 E
Component: 1S AIRBAG VW8R 024 6300
Revision: 03024000 Serial number: 0037KD028DF
Coding: 0012627
Shop #: WSC 00066 000 00000
VCID: 2E53B26FB90C649

Part No: 1K0 959 339 B
Component: BF-Gewichtsens. 006 0003

1 Fault Found:
00532 - Supply Voltage B+
002 - Lower Limit Exceeded - Intermittent

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Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 L HW: 1K0 953 549 L
Component: Lenksäulenmodul 013 0040
Coding: 0000041
Shop #: WSC 00066 000 00000
VCID: 3B758B3B7A7E811

No fault code found.

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Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No: 1K0 920 972 LX
Component: KOMBIINSTRUMENT 3HL 4312
Coding: 0023203
Shop #: WSC 08220 444 58805
VCID: 8D1195E3944AFF1

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory

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Address 19: CAN Gateway Labels: 1K0-907-530.lbl
Part No SW: 1K0 907 530 E HW: 1K0 907 951
Component: Gateway H11 0110
Revision: 11 Serial number: 29001053190646
Coding: 3D3F0B400F1002
Shop #: WSC 00066 000 00000
VCID: 2959417380E2031

No fault code found.

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Address 1C: Position Sensing Labels: 1Kx-919-xxx-1C.lbl
Part No SW: 1K5 919 965 HW: 1K5 919 965
Component: Kompass 002 0001
Revision: 00002000 Serial number: 0371356TP99903
Shop #: WSC 00000 000 00000
VCID: F8FFD4378BC8EA9

1 Fault Found:
00926 - Terminal 30
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 3
Fault Frequency: 1
Reset counter: 178
Mileage: 274223 km
Time Indication: 0
Date: 2000.00.00
Time: 00:00:55


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Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No: 1K0 920 972 LX
Component: IMMO 3HL 4312
Shop #: WSC 08220 444 58805
VCID: 8D1195E3944AFF1

No fault code found.

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Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN2.lbl
Part No: 1K0 959 701 K
Component: Tuer-SG 024 2339
Coding: 0001271
Shop #: WSC 00066 000 00000
VCID: 36639A0F415C5C9

1 Fault Found:
01811 - Supply Voltage for Door Controller; Drivers Side (J386)
002 - Lower Limit Exceeded - Intermittent

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Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb
Part No: 1K1 909 144 H
Component: EPS_ZFLS Kl.2 1502
Shop #: WSC 00000 000 00000
VCID: 306FAC17A338729

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory - MIL ON
Freeze Frame:
Mileage: 4200 km
Temperature: 17.0°C
Voltage: 14.30 V
Voltage: 14.10 V


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Address 46: Central Conv. Labels: 1K0-959-433-MAX.clb
Part No SW: 1K0 959 433 AT HW: 1K0 959 433 AT
Component: 01 KSG PQ35 G2 010 0101
Revision: 00010000 Serial number: 00000000000000
Coding: 13100F880106281B0906050FA0080F0490A540
Shop #: WSC 00066 000 00000
VCID: 820BB6DFDD14B09

Part No: 1K0 951 605 C
Component: LIN BACKUP HORN H03 1301

Component: NGS n.mounted

Component: IRUE n.mounted

1 Fault Found:
00668 - Supply Voltage Terminal 30
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00110010
Fault Priority: 4
Fault Frequency: 3
Reset counter: 178
Mileage: 0 km
Time Indication: 0


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Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN2.lbl
Part No: 1K0 959 702 K
Component: Tuer-SG 024 2339
Coding: 0001271
Shop #: WSC 00066 000 00000
VCID: 377D970B4656A51

1 Fault Found:
01812 - Supply Voltage for Door Controller; Pass. Side (J387)
002 - Lower Limit Exceeded - Intermittent

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Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No SW: 1K0 035 180 A HW: 1K0 035 180 A
Component: Radio DE2 008 0115
Revision: 00008000 Serial number: VWZ4Z7E3035745
Coding: 0040400
Shop #: WSC 00066 000 00000
VCID: 1E3362AFC9ACF49

1 Fault Found:
01305 - Databus for Infotainment
014 - Defective - Intermittent

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Address 62: Door, Rear Left Labels: 1K0-959-703-GEN2.lbl
Part No: 1K0 959 703 D
Component: Tuer-SG 021 2416
Coding: 0000144
Shop #: WSC 00066 000 00000
VCID: 3169A913A8327B1

1 Fault Found:
01813 - Supply Voltage for Door Controller; Rear Left (J388)
002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels: 1K0-959-704-GEN2.lbl
Part No: 1K0 959 704 D
Component: Tuer-SG 021 2416
Coding: 0000144
Shop #: WSC 00066 000 00000
VCID: 326BA61FAD34409

1 Fault Found:
01814 - Supply Voltage for Door Controller; Rear Right (J389)
002 - Lower Limit Exceeded - Intermittent

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Address 7D: Aux. Heat Labels: 1K0-963-235.lbl
Part No SW: 1K0 963 235 E HW: 1K0 963 235 E
Component: PTC-Element 0404
Revision: 00800000 Serial number:
Shop #: WSC 00000 000 00000
VCID: 2D51B563B40A1F1

1 Fault Found:
01299 - Diagnostic Interface for Data Bus (J533)
013 - Check DTC Memory

End ---------------------------------------------------------------------

I ordered a G28 sensor, no local dealer had one in stock, and if that doesn't do it (I'm guessing it probably won't) will start electrically testing all the harness wires. Does anyone have any other ideas?

Thanks
Tony

It is probably because of G28. Good that you start with it.

I have a car here with pretty much the exact same problem. I pulled as much of the harness coverings loose as I could, didn't really see anything BUT it does have a lot of chaffing inside the fluting. Pulled the trans, checked/replaced the rear sealing flange w/ sensor ring, and the CKP sensor itself... no dice.

Pulled the harness loose AGAIN, still didn't see anything obvious, but while it was running I was able to wiggle it around and get the EGR valve to spaz out, idle speed to wobble, and some other strange behavior.

Engine harness is on national backorder, I have one red ordered by VIN right now, we'll see.

I've run across a similar problem with a BRM car before, but was able to pinpoint the bad spot in the harness (which is why I went after that first). This one, no such luck. But it has chaffing all over it (it is a mess, actually). Just cannot pinpoint for certain any bad spots in any of the 3 CKP sensor wires.

oilhammer said:

I have a car here with pretty much the exact same problem. I pulled as much of the harness coverings loose as I could, didn't really see anything BUT it does have a lot of chaffing inside the fluting. Pulled the trans, checked/replaced the rear sealing flange w/ sensor ring, and the CKP sensor itself... no dice.

Pulled the harness loose AGAIN, still didn't see anything obvious, but while it was running I was able to wiggle it around and get the EGR valve to spaz out, idle speed to wobble, and some other strange behavior.

Engine harness is on national backorder, I have one red ordered by VIN right now, we'll see.

I've run across a similar problem with a BRM car before, but was able to pinpoint the bad spot in the harness (which is why I went after that first). This one, no such luck. But it has chaffing all over it (it is a mess, actually). Just cannot pinpoint for certain any bad spots in any of the 3 CKP sensor wires.

Click to expand...

Wow, national back order! I'm glad I got mine before that.

After fixing too many chafed spots in my harness. I was understood that I was not going to be able to find them all and replaced the harness. Problem disappeared.

National back order tends to indicate the "Just in Time" inventory system is not in time & many other BRMS are experiencing this problem. Thanks again to JoeTDI.

Well we are talking about what is now at its youngest a 6 year old car, and a VERY small production run at that. So it doesn't really suprise me that the harness isn't readily available all the time.

While it does seem to be somewhat common (I have seen it before, and have certainly read a lot about it here) it has only reared its ugly head now twice for me, and I see a LOT of BRM cars. I think the manuals are worse, though, given the rocking of the engine.

oilhammer said:

I think the manuals are worse, though, given the rocking of the engine.

Click to expand...

+1 Perhaps a bit of luck of the draw as to how tight the champs are cinched.

Update: G28 just arrived, not yet installed, while waiting I did attempt to pinch, wiggle and manipulate the harness while running. I experienced no strange behavior of any kind. I'm sure it's the harness, I just wish I had some tangible evidence that it is.

Harness came in yesterday afternoon, had to finish another job up, but will be getting back on this Jetta this morning. I'll keep everyone posted as to the resolution.

Got the harness in, seems to run fine now, but I have a mystery hard fault for the G212 EGR potentiometer. Will not clear, at all. It started flagging this DTC right before I took the car apart. My other mystery issues have gone away, and the car runs well again.

001032/16792/P0408 EGR pot signal too high

I did try a different EGR valve assembly, same thing.

My car is fixed! G28 sensor replaced, no more faults, no more stalling, car runs perfectly. Yes replacing that sensor is a PITA, but it appears to be the cause of all my car's problems.

You will know as the rain, snow & salt hit your roads. If it was more than the G28 sensor, you will soon find out.

Bob S. said:

You will know as the rain, snow & salt hit your roads. If it was more than the G28 sensor, you will soon find out.

Click to expand...

+1......as I did

Fixer glad to hear you got it fixed!

brianstrange said:

+1......as I did

Click to expand...

And thats why I replaced my harness before winter. I certainly didnt want to deal with corrosion from salt on exposed wire.

Yeah, this car here was "fixed" with a new G28 for several miles too, before I too ordered a new harness.

Update: Since replacing the G28 sensor my car has gone ~20 driving cycles and 800 miles or so without any hint of the problems that prompted my original post.