2006 BRM Jetta limp mode, weirdness

[BTRDMI]

Hello everyone. I’m at a wits end with this car, and I’m near ready to burn it. I have a 2006 Jetta TDI, 256 thousand kilometres, and I’ve been having limp mode woes. The issues began last weekend. Was about to get onto the highway, limp mode. The previous owner forgot to inform me that he unplugged the EGR. I plugged it back in, cleared the codes, and all was well.. for a week. This weekend, the issues arose again. I had it stage 1.5 Tuned Friday (the EGR was mapped out) and Saturday the limp mode hell began. It’s quite intermittent, usually seems to happen if I’ve been idling for periods of time. Tonight, I learned that if I unplug the EGR, I get immediate limp mode. I can restart it, and it will go directly into limp mode. I’m not exactly sure what’s going on, but is it a possibility for a stuck EGR valve to cause Limp? I couldn’t get a straight answer from the previous owner, however he did tell me someone did something to the EGR valve.. my guess is maybe it’s stuck open a little? I’m not sure… please help

 

[Windex]

Best way to diagnose limp mode is to scan and run a log of boost pressure with VCDS. Do you have access to VCDS?

 

[BTRDMI]

Not at this time, my VCDS cable is on its way, Please don’t beat me . I suppose I’m just utterly confused. When the car isn’t in limp mode, it works beautifully, and it’s very intermittent. There isn't a set number of steps to get it to limp, it just does it at random. The most intriguing issue I’m having though, is the fact that unplugging the EGR causes immediate limp. The EGR was unplugged last weekend, and was driven previously with it unplugged. Can a partially stuck open EGR valve cause limp? Or EGR issues in general cause limp?

 

[Rx7145]

What do you mean by unplug the EGR? unplug the vacuum line or the electric wires?
Would be interesting to do the zip tie mod and see if it changes anything that would rule out veins in the turbo.

 

[Vince Waldon]

The low power troubleshooting proceedure listed in my sig is a good way to work thru it methodically, and yup you'll need your new VCDS,

 

[BTRDMI]

I’m unsure of where the vacuum line is on the EGR. However, I did mean the electric plug. I would like to play with this Zip tie mod, if someone had a good explanation of how it worked. I haven’t pulled the EGR out yet, but I was told by the previous owner that it had been altered in some way to stay closed physically. I had the car tuned on Friday, 1.5 Dynamic Idle, smoke tune, immo delete & EGR delete. The EGR delete I guess just holds the EGR closed, but if there’s a mechanical fault with the EGR, maybe it’s stuck open a little, could that be a boost leak? What really confuses me, is why unplugging it causes the immediate limp. As soon as I start the car, it’s in limp, but once I plug it back in, everything is normal again.

 

[Vince Waldon]

Your EGR is electronic, no vaccum hose.

As i re-read your posts it doesn't sound like classic limp-mode actually, which is generally normal power untill the turbo is stressed and then the engine derates the turbo to prevent damage.

You seem to be describing an engine that can be weak as soon as it's started?

If so, perhaps you have the more classic BRM "leaky EGR valve"... the EGR actuator or valve itself gets worn/full of carbon and no longer closes every time it's told to do so. When it stays open, even just a bit, unmetered air enters the engine and confuses things; the end result...low power.

To check (you'll need VCDS):

- disconnect the electrical connection on the EGR valve
- remove the EGR valve from the manifold
- reconnect it electronically, and place it on top of the engine somewhere you can watch it work
- with the key in the "on" position use VCDS's Output Tests to cycle the EGR, and look to see if you can see daylight thru it when it's supposed to be fully closed

If you determine it's not closing all the way every time you can sometimes get away with cleaning it, but many times it's the internal actuator that's worn and that's not really cleanable.

 

[BTRDMI]

It’s for sure difficult to explain. It doesn’t seem to be triggered by stresses such as passing another car or going up hill. It could go into limp as soon as I pull away from a stop light. The EGR has been tuned out, and I was told the tune holds the valve closed at all times. I’m curious as to why, if I unplug my EGR valve (which no longer serves a purpose mind you) my car goes directly into limp mode. I’m thinking the valve itself may be damaged, maybe it’s not closing properly, I would just like to know if an EGR valve that’s stuck open slightly can cause the issues I’m describing. It’s definitely a limp mode of some kind, as everything seems to go back to normal if I restart the car (unless the EGR is unplugged)

 

[Vince Waldon]

Your tuner may have tuned it out completely, or just tuned the ECU to ignore the readings, but in any event I'd say just test it and either confirm or rule it out as a cause. You can pull the valve out right now, even before you get your VCDS, and see if it's all gummed up and not closing.

I have experienced your exact symptoms (as I understand them) on a BRM...low power that appears to be related to EGR function, and I've told you how I tracked it down.

 

[BTRDMI]

Correct. I’m just trying to express that the car does in fact go into limp, not low power. If I restart the car, it comes back to normal again, but with the EGR unplugged, it’s immediate limp.

 

[BTRDMI]

Hey everyone. Here’s the VCDS Data.
Sunday,30,January,2022,14:37:34:28589
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 21.9.0.2 (x64)
Data version: 20210903 DS330.0
www.Ross-Tech.com


VIN: 3VWNT71K56M689042 License Plate: ERIC
Mileage: 257970km-160295mi Repair Order:



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


Chassis Type: 1K (1K0)
Scan: 01 03 08 09 15 16 17 19 1C 25 36 42 44 46 52 56 62 72 7D

VIN: 3VWNT71K56M689042 Mileage: 257970km-160295miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 1010
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: Malfunction 0010
1C-Position Sensing -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
36-Seat Mem. Drvr -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: Malfunction 0010
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
7D-Aux. Heat -- Status: Malfunction 0010

-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-016-BEW.lbl
Part No SW: 03G 906 016 AB HW: 028 101 223 8
Component: R4 1,9L EDC G000SG 7550
Revision: --H01--- Serial number: VWZ7Z0E2566212
Coding: 0050071
Shop #: WSC 66565 257 00032
VCID: 63C5EC69A23A15913C-8036
VINID: 0E69DE90705B14674620900408907391D3

1 Fault Found:
000258 - Mass Air Flow Sensor (G70)
P0102 - 000 - Signal too Low - Intermittent
Freeze Frame:
Fault Status: 00110000
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 257350 km
Time Indication: 0
Date: 2000.00.00
Time: 22:18:21

Freeze Frame:
RPM: 1386 /min
Speed: 0.0 km/h
Load: 0.0 %
Duty Cycle: 100.6 %
Bin. Bits: 00101111
Mass Air / Rev.: 305.0 mg/str
Mass Air / Rev.: 0.0 mg/str

Readiness: 0 0 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1K0-907-379-MK70.lbl
Part No: 1K0 907 379 P
Component: ASR FRONT MK70 0105
Coding: 0017025
Shop #: WSC 00066 000 00000
VCID: 3F8D00196E12117178-806A

1 Fault Found:
00668 - Supply Voltage Terminal 30
002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 1K0-820-047.lbl
Part No: 1K0 820 047 DG
Component: Climatic PQ35 090 0505
Shop #: WSC 00000 000 00000
VCID: 6CD787554FE45AE98D-8038

2 Faults Found:
00229 - Refrigerant Pressure
002 - Lower Limit Exceeded - Intermittent
01317 - Control Module in Instrument Cluster (J285)
013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 3C0-937-049-23-H.lbl
Part No SW: 3C0 937 049 E HW: 3C0 937 049 E
Component: Bordnetz-SG H37 1002
Revision: 00H37000 Serial number: 00000000167184
Coding: 10018E234004180000140000001400000028770B5C
Shop #: WSC 91476 999 00150
VCID: 2B5544498A6A9DD1C4-807E

Subsystem 1 - Part No: 1K1 955 119 C Labels: 1KX-955-119.CLB
Component: Wischer VW350 012 0402
Coding: 00065493
Shop #: WSC 91476

3 Faults Found:
01314 - Engine Control Module
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00110100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 92
Mileage: 256135 km
Time Indication: 0

Freeze Frame:
ON
Voltage: 12.10 V
ON
ON
OFF
OFF
OFF

00446 - Function Limitation due to Under-Voltage
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 4
Fault Frequency: 3
Reset counter: 119
Mileage: 255787 km
Time Indication: 0

Freeze Frame:
ON
Voltage: 10.15 V
OFF
ON
ON
ON
OFF

02381 - Windshield Wiper Motor; Overload
003 - Mechanical Failure - Intermittent
Freeze Frame:
Fault Status: 00100011
Fault Priority: 2
Fault Frequency: 127
Reset counter: 125
Mileage: 257863 km
Time Indication: 0

Freeze Frame:
ON
Voltage: 14.00 V
ON
ON
OFF
OFF
OFF


-------------------------------------------------------------------------------
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: 0037KD03ZW0R
Coding: 0012627
Shop #: WSC 00066 000 00000
VCID: 2E534D5DB978E8F9E3-807A

Subsystem 1 - Part No: 1K0 959 339 E
Component: BF-Gewichtsens. 006 0005

Subsystem 2 - Serial number: 6332MSME0A79264EN

Subsystem 3 - Serial number: 6342MSME0A6404196

Subsystem 4 - Serial number: 6351HSME0811460A/

Subsystem 5 - Serial number: 6361HSME08171B7EH

Subsystem 6 - Serial number: 63727SME077B5C6DL

Subsystem 7 - Serial number: 63827SME07742000O

3 Faults Found:
01217 - Side Airbag Igniter; Driver Side (N199)
001 - Upper Limit Exceeded - Intermittent - MIL ON
01218 - Side Airbag Igniter; Passenger Side (N200)
001 - Upper Limit Exceeded - Intermittent - MIL ON
00532 - Supply Voltage B+
002 - Lower Limit Exceeded - Intermittent - MIL ON

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 AJ HW: 1K0 953 549 AJ
Component: J0527 034 0070
Coding: 0002021
Shop #: WSC 00066 000 00000
VCID: 7AFBB10D35B0F4590F-802E

Subsystem 1 - Part No: XXXXXXXXXXX
Component: E0221 007 0050

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No: 1K0 920 872 D
Component: KOMBIINSTRUMENT 3HL 1212
Coding: 0024303
Shop #: WSC 00066 000 00000
VCID: 2C5747558F649AE9CD-8078

1 Fault Found:
00779 - Outside Air Temp Sensor (G17)
010 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:. 1K0-907-530-V1.clb
Part No SW: 1K0 907 530 F HW: 1K0 907 951
Component: Gateway H10 0120
Revision: H10 Serial number: 28001057288210
Coding: 3D7F0B400F1002
Shop #: WSC 00066 000 00000
VCID: 2A5B414D859084D93F-807E

1 Fault Found:
01314 - Engine Control Module
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 92
Mileage: 256135 km
Time Indication: 0
Date: 2000.00.00
Time: 17:28:27


-------------------------------------------------------------------------------
Address 1C: Position Sensing Labels: 1Kx-919-xxx-1C.lbl
Part No SW: 1K5 919 965 A HW: 1K5 919 965 A
Component: Kompass 005 0003
Revision: 00005000 Serial number: 1293324T0DTP01
Coding: 0000003
Shop #: WSC 00066 000 00000
VCID: 39796E0170363F4146-806C

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No: 1K0 920 872 D
Component: IMMO 3HL 1212
Shop #: WSC 00000 000 00000
VCID: 2C5747558F649AE9CD-8078

No fault code found.

-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr Labels: 3C0-959-760.lbl
Part No SW: 3C0 959 760 B HW: 3C0 959 760 B
Component: Sitzverstellung 0701
Revision: 00003000 Serial number: 00000000000000
Shop #: WSC 00000 000 00000
VCID: 2C5747558F649AE9CD-8078

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN2.lbl
Part No: 1K0 959 701 K
Component: Tuer-SG 024 2377
Coding: 0001269
Shop #: WSC 00066 000 00000
VCID: 3663653D4128D039AB-8062

1 Fault Found:
00932 - Electric Window Motor; Drivers Side (V147)
005 - No or Incorrect Basic Setting / Adaptation - Intermittent

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-144-G2V2.clb
Part No: 1K1 909 144 J
Component: EPS_ZFLS Kl.5 D04 1606
Shop #: WSC 00000 000 00000
VCID: 326B592DAD40CC1987-8066

No fault code found.

-------------------------------------------------------------------------------
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: 13900E880106281B0904050FB0080F0480A540
Shop #: WSC 00066 000 00000
VCID: 020BC9ED5D60BC9957-8056

Subsystem 1 - Component: Sounder n.mounted

Subsystem 2 - Component: NGS n.mounted

Subsystem 3 - Component: IRUE n.mounted

1 Fault Found:
00930 - Locking Module for Central Locking; Rear Left (F222)
012 - Electrical Fault in Circuit - Intermittent
Freeze Frame:
Fault Status: 00101100
Fault Priority: 4
Fault Frequency: 12
Reset counter: 112
Mileage: 255393 km
Time Indication: 0
Date: 2000.00.00
Time: 21:26:14


-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN2.lbl
Part No: 1K0 959 702 K
Component: Tuer-SG 024 2377
Coding: 0001269
Shop #: WSC 00066 000 00000
VCID: 377D683946222931B0-8062

3 Faults Found:
00933 - Electric Window Motor; Passenger Side (V148)
012 - Electrical Fault in Circuit - Intermittent
01553 - Motor for Central Locking; Passenger Door (V57); Lock
012 - Electrical Fault in Circuit - Intermittent
00929 - Locking Module for Central Locking; Front Passenger Side (F221)
008 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.clb
Part No SW: 1K0 035 180 D HW: 1K0 035 180 D
Component: Radio DE2 011 0014
Revision: 00011000 Serial number: VWZ4Z7E3049303
Coding: 0010400
Shop #: WSC 00000 000 00000
VCID: 2149A661F8A647816E-8074

1 Fault Found:
00003 - Control Module
014 - Defective

-------------------------------------------------------------------------------
Address 62: Door, Rear Left Labels: 1K0-959-703-GEN2.lbl
Part No: 1K0 959 703 D
Component: Tuer-SG 021 2434
Coding: 0000144
Shop #: WSC 00066 000 00000
VCID: 31695621A846F701FE-8064

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels: 1K0-959-704-GEN2.lbl
Part No: 1K0 959 704 D
Component: Tuer-SG 021 2434
Coding: 0000144
Shop #: WSC 00066 000 00000
VCID: 326B592DAD40CC1987-8066

No fault code found.

-------------------------------------------------------------------------------
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: 2D514A51B47E93E1DA-8078