SOLVED! 2004 Manual swapped BEW low power help

Mozambiquer

Vendor , w/Business number
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Mar 21, 2015
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Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
I picked up a cheap 2004 BEW Jetta with 215k miles on the odometer for pretty cheap recently, and am working on fixing it up for a family member. The previous owner manual swapped it, but it was done rather poorly... They also did an EGR delete at the same time and said it was in limp mode ever since.
Well, I started in and replaced the original timing belt!!! :eek::eek::eek: the camshaft and lifters, and threw away the cone air filter. Installed an air box and a replacement MAF sensor (I do need to make sure it is the right part though...) Itook it out for a rip, and found it had no power. Pulled back in and went over the vacuum lines, they were a MESS! I pulled them off and sorted them out, and got it all back together, replaced the vacuum pipe to the brake booster that was cracked, and tightened the vacuum nipple. Now there is 30 in/hg vacuum. I then found the intercooler was leaking, as was one of the boost pipe o-rings. Got a new intercooler and replaced the o-rings, and now I request vs actual boost is finally correct, but it is only requesting around 1700MB.

So, my question is, could some of it have to do with the ECM not seeing the vehicle speed (I mentioned the car was hacked together...) and cutting back the fuel because of that? I kinda wish I had gotten it as an auto and did the manual swap myself, as then there would be an easier time with getting everything sorted, as it would be a clean slate, but anyway... I can't really complain too much, it was cheap lol.
 

oilhammer

Certified Volkswagen Nut & Vendor
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outside St Louis, MO
TDI
There are just too many to list....
Why isn't the ECU seeing the vehicle speed? Not sure what they would do without that input, but that certainly is a problem.

The intake port runner control working?
 

Mozambiquer

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Mar 21, 2015
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Versailles Missouri
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2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Why isn't the ECU seeing the vehicle speed? Not sure what they would do without that input, but that certainly is a problem.

The intake port runner control working?
The person who did the manual swap didn't do the wiring... I plan to get started in on that next, probably going to do the ABS based, as thats a lot easier from what I understand. The intake port runner control was disconnected by the previous owner as well... I may try to get it re-connected, since it is still in there.
 

Mozambiquer

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Joined
Mar 21, 2015
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Versailles Missouri
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2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Cant delete the EGR on a BEW without a tune. Will just go right into limp mode. Does it have a tune?
I've driven several bew cars with no tune and an egr delete. And they weren't in limp mode.
I wish people didn't have the false idea that egr is always bad lol.
 

burpod

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cape cod, ma
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82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
I've driven several bew cars with no tune and an egr delete. And they weren't in limp mode.
I wish people didn't have the false idea that egr is always bad lol.
you can delete those silly intake runner flaps with a tune too. useless crap! :)
 

Mozambiquer

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2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
you can delete those silly intake runner flaps with a tune too. useless crap! :)
Yep, I need to pull the file and get it sent to you...
 

oilhammer

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outside St Louis, MO
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There are just too many to list....
Cant delete the EGR on a BEW without a tune. Will just go right into limp mode. Does it have a tune?
You can unplug the EGR valve on a BEW, and it will continue to power itself perfectly fine. Not sure where you got that information, but it is not correct. The only way you'd know something was messed with is the MIL will be one, and the engine may be a teeny bit more diesel-sounding at idle, that's it. BHW is the same way.
 

mittzlepick

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union maine
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2004 jetta wagon (365k)2001 wagon tire burner 6spd 2003 wagon(417k)
Same plug for auto v.s. manual for speed sensor unless its not a normal 5 speed or euro spec 6 speed. At least im pretty sure ive done 4 swaps but its been a bit since
 

oilhammer

Certified Volkswagen Nut & Vendor
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outside St Louis, MO
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There are just too many to list....
You sure about that? This is the Jatco 09A here, not the VAG 01M.

May want to read here:

Self-Study Programme 232 5-Speed Automatic Gearbox 09A/09B (volkspage.net)

(hint: the VSS is INSIDE the transmission, it is not mounted externally on the final drive like the 01M and manuals)

The ECU on 09A-equipped cars gets its VSS signal via the TCM. It doesn't have its own way of getting it through the old style VSS. But there is a way to pick up the vehicle speed signal across the CAN bus from the ABS module, which is how all the later cars do it anyway.
 
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DuraBioPwr

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Jan 28, 2020
Location
Eastern Washington
TDI
2004 BEW Jetta (5spd)
You can unplug the EGR valve on a BEW, and it will continue to power itself perfectly fine. Not sure where you got that information, but it is not correct. The only way you'd know something was messed with is the MIL will be one, and the engine may be a teeny bit more diesel-sounding at idle, that's it. BHW is the same way.
I just went through this on my daughters 2006 Beetle BEW. Kept going into limp mode over over P0402 if I remember right (there were one or two more codes associated with EGR flow as well). Hooked up VCDS and tracked EGR flow desired vs. actual and it was off. The EGR valve was failing. In the process of diagnosis I swapped the EGR valve onto my 2004 Jetta BEW and it then limped within several miles. And my 2004 has a Malone dynamic EGR tune (stage 2 power wise)!

I dont know what you guys are working on but BOTH of my BEWs limp without proper EGR flow. The computer most certainly knows its off and limits boost to about 8psi.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Worked on hundreds of them.... never seen or known this to happen, and I've seen plenty of people who unplugged the EGR valve right away when the car was new (and had the MIL staring them in the face the whole time).... they all ran perfectly fine power-wise.
 

DuraBioPwr

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Jan 28, 2020
Location
Eastern Washington
TDI
2004 BEW Jetta (5spd)
Well I certainly didnt want to spend the $300 on a new EGR valve but it was that or a tune for $500 to delete it. Mine limp 100%. My guess is thats the problem with the OPs car too. He states the previous owners deleted it and now in low power mode. Its LIMPED!
 

Mozambiquer

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Versailles Missouri
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2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Got it fixed! I hacked the instrument cluster with KW1281TEST software to read vehicle speed by CAN through the ABS sensors, and then got a tune from @burpod to change the software to manual and to tune out all the things that were removed by the previous owner.
I took off and burned rubber in first and second gear as I took off! Had to back off to keep from burning up the tires lol.
 
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