2009 Scirocco 2.0L GT TDI 170bhp CBDB Hard start / Rough Idle

[campbell1987]

Hi all, I have here a 2009 VW Scirocco 2.0tdi with CBDB Engine, We got it from an auction site without seeing it first.
It cranks slow at 184RPM, Battery replaced with known good one from a BMW, Resting voltage on it is 12.4v and it delivers just under 800CCA (794 to be exact) With charger/boost pack i get it closer to 1000CCA and still the car cranks slow. Replaced starter with another junkyard unit but still same slow crank. I also tried a jump lead from battery negative to starter body and that made no difference so guessing its not a ground issue. I have done a voltage drop test on any visible ground points and removed and wire brushed all ground connections. 2 had corrosion and 1 threaded ground stud even had a few layers of paint from previous accident damage repair job. Hoping this hasn't damaged any control units/modules.
I have noticed that one of the motorized flaps below the stereo is constantly moving with key on engine off and all blower fans set to off. Even with fans turned on it still constantly moves by itself,
I also noticed that with key on engine off and glow plugs disconnected the car still pulls nearly 10 amps at 13v.... Is this normal? And the inrush current when battery is connected is greater than 20amps.??? I have went over all fuses using the voltage drop test to see each circuits current draw and cant find any large loads active in either of the 2 fuse boxes.

Also i noticed fuel pumps do not prime the system when key is turned on, But i can command them on in delphi DS150
Is this normal???

Lastly I noticed the EGR housing body has 12v between it and battery negative. Thinkin maybe this is to do with previous owners EGR blank job. They left the pipe that connects Turbo to EGR disconnected so thinking EGR is grounded through that pipe? With a test light hooked up to battery negative and EGR body it lights up. It only goes out when i remove R1 Relay from engine bay fuse box.???

I have no wiring diagrams to help and even if i did im not sure where to go from here.
Have a brand new starter motor here to try later but dont think that is the problem. Though original has been worn out almost with all the cranking. Metal inside looks discolored from excess heat.
Had a glance behind stereo for wiring mods/mistakes but all looks standard.

Here are a few videos of it. When we first got it i did eventually get it to start but it produced white smoke and diesel smell so long story short all fuel side of things got redone including injectors and is all verified to be working ok now.

https://youtu.be/Yh3JUPFILiM


Here is ECU info, Used Carista not VCDS
(Airbags on the way so ignore them codes)

ECU info obtained with Carista 5.3 for Android:

VIN: WVWZZZ13ZAV415741

Engine
Part #: 03L906022KD
Component: R4 2,0L EDC 0000
Coding: 1072 (decimal)
[No fault codes]

ABS
Part #: 1K0907379AN
Component: ESP MK60EC1
Coding: 763B40F5092300FF6E1202E8901A00823000 (hex)
[No fault codes]

Steering angle
[ECU not present]

Power steering
Part #: 1K0909144P
Component: EPS_ZFLS Kl. 000
Coding: [none]
[No fault codes]

Airbags
Part #: 1K0909605AE
Component: 0H AIRBAG VW8
Coding: 12360 (decimal)
Fault codes:
01218 Side Airbag Igniter: Front Passenger Side (N200)
01228 Airbag Cut-Off Switch for Passenger Side (E224)
02756 Redundant signal path of Airbag cut-off switch - front passengerside (E224)

Suspension
Part #: 3C0907376A
Component: DAEMPFUNGS-SG
Coding: 000180 (hex)
[No fault codes]

Instrument cluster
Part #: 1K8920971A
Component: KOMBI
Coding: 470B00 (hex)
[No fault codes]

Immobilizer
Part #: 1K8920971A
Component: IMMO
Coding: [none]
[No fault codes]

Central electronics
Part #: 5K0937086
Component: BCM PQ35 M
Coding: 4E100A389037E100408800843400012643513B88436D81605C8000000000 (hex)
Fault codes:
00153 Left Windshield Wiper Motor (V216)
00978 Lamp for Low Beam; Left (M29)
00979 Lamp for Low Beam; Right (M31)
01134 Alarm Horn (H12)
01493 Bulb for Blinkers, Front Left (M5)
01495 Bulb for High-Beams, Left (M30)
01496 Bulb for Fog-Lamps, Left (L22)
01497 Bulb for Blinkers, Front Right (M7)
01499 Bulb for High-Beams, Right (M32)
01500 Bulb for Fog-Lamps, Right (L23)
02395 Parking light right front (M3)

Body/convenience system
[ECU not present]

Driver's door
Part #: 1Q0959701H
Component: Tuer-SG
Coding: 16949 (decimal)
[No fault codes]

Front passenger's door
Part #: 1Q0959702H
Component: Tuer-SG
Coding: 16948 (decimal)
Fault codes:
00110 Lamp for mirror turn signal front seat passenger side (L132)

Steering wheel
Part #: 1K0953549CF
Component: J0527
Coding: 502 (decimal)
[No fault codes]

Heater & air conditioning
Part #: 1K0907044CT
Component: ClimatronicPQ35
Coding: [none]
Fault codes:
01592 Air Quality Sensor (G238)

Radio
Part #: 3C8035195
Component: RCD510
Coding: 0500040004 (hex)
Fault codes:
03272 Control Module for Audio Interface

CAN network gateway
Part #: 1K0907530AA
Component: J533 Gateway
Coding: E9881F06000212004001 (hex)
Fault codes:
03272 Control Module for Audio Interface

Media player
[ECU not present]

 

[campbell1987]

Also done injector leak off test and that was all good. Even tried replacement injectors.
And tried removing MAF sensor but problem persists.

 

[jimmyfine]

Don't know if this helps or not, but my 2010 JSW is/was having the same slow crank issue as your having. It was cranking at about 150-180rpm so I went through all of the stuff you did and got no improvement except it held about 160-170rpm more steadily so I figured the starter brushes must be wearing out. I pulled the starter and removed the back plate to check the brushes and found that 1 was stuck and not contacting the commutator bars, after blowing out the dust and working the brushes around they were all making contact and it now reliably makes between 180-190rpm.

I know this is still low as 200rpm is recommended for normal operation, but mine was occasionaly doing a false start where it would fire a couple times but fail to start. It has not done that since I messed with the starter brushes.