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Columbusracing
09-01-2013, 07:13 PM
2004 Golf Mk5 1.6 FSI BAG engine

Cruise control inoperable and the brake lights illuminate and stay on constantly when the ignition is turned on when the ignition is off brake light works as it should when engine is running.
Had the following code:

16955 - cruise control brake switch A

I have swapped the brake light switch with a replacement which made no difference. Must be a short somewhere due to the power to the brake lights when ignition is off.

Anyone any ideas or experiences?

Seen another similar thread with no solution anyone got any ideas

owler
12-01-2013, 03:52 PM
It sounds like the switch as I had a similar fault and code 16955 showed up on diagnostic test. Thinking about why the switch has two sets of contacts it makes sense that one side is for the cruise control while the other is for brake lights.
The new switch has rectified all faults but there are multiple switches so make sure it is the correct one for your car.

Crasher
12-01-2013, 04:06 PM
Are the lights on if you unplug the harness from the switch?

Columbusracing
17-01-2013, 12:53 AM
sorry for the late reply didn't ever turn the ignition on with the switch off so not sure but will have to ask my mate to try it. Thats a good idea though would point to whether theres just a direct short making the switch redundant.
cheers

Columbusracing
05-03-2013, 06:53 PM
Little update have tried with the switch unplugged but makes no difference brake lights are on with ignition. With the ignition on the lights are on - removing all the fuses from the fascia fuse box the only one to effect the brake lights is to remove the fuse 29 engine management.

I can shut them off removing a couple of fuses from the engine bay fuse box aswell.
Fuse 16 - Steering Column Control Function
Fuse 26 - engine management
Fuse 40 - Fascia Fuse board

Does anyone know if the multifunction unit that control the rear lights has a connection to the engine ecm?
The multifunction unit for the brake lights has a number of relays on but i cannot find anything to tell what they are.

Are multifunction units common on these?

Cheers

Crasher
06-03-2013, 11:20 AM
The brake lights are individually powered from the "J519 Onboard supply control unit" from two different multi-plugs so the problem lies within the J519, either it is faulty or is being commanded to turn on the brake lights. You need to observe the J519’s switch inputs in Measuring Blocks 08 using a diagnostic computer. You don’t mention fuse 14 extinguishing them so that rules out the input to the pedal switch. In the absence of a diagnostic computer, I would check for ignition on power at the black/red wire on the brake light switch plug when it is unplugged from the switch. If it does have power, take out the dash side fuses one by one and see if the power goes and also try the engine bay fuses again. Removing these fuses will cause fault codes that will have to be cleared.

Columbusracing
06-03-2013, 11:02 PM
Well the car has lost 5/6 th gears aswell which is nice and my mate who owns it has gotten a train home so i have a little time to play with it. Will have to see what options i have with my diag gear don't have vcds at the moment but should have something to check it with.

Will check for 12v on the brake switch terminals if there is 12v with the fuse out on either terminal then maybe a short in the circuit feeding the J519.

Gonna have to pull the box out and send it for repair seems to have a selector shaft problem all the linkage moves as it should but gearbox doesn't select gears in the fifth or six position. I even pulled out the linkage on the box and moved the selector which the linkage should have been actuating and still no gear selected.

trs888
17-03-2013, 07:58 PM
i came back to the car to find my brake lights on when it was locked. happened twice, so i contacted my VW mate, he said probably the J519 unit. he had a similar thing on an R32 earlier in the week.

he suggested disconnecting it for up to 15 mins, and then plugging it back in. does a kind of reset.

might work for you, i havent tried as yet due to bad weather!

worth a shot tho!

Columbusracing
09-04-2013, 03:55 PM
Finally got the golf out again to play with today and want to get the brake lights sorted before taking the box out so got my new vag com out and had a little play.
Ignition off brake switch operates normally -09 central electronics - brake switch open 1% brake switch closed 100%.
Turn on ignition and brake switch stays 100% if you go into engine with ignition on its 100% aswell manipulating switch makes no difference. Checked the voltages with my power probe all good switch operates as it should.
Tried pulling fuses again and relays with the multifunction fuses and control relay removed brake lights still on. As i've said before only engine management fuses turn them off. Fuse 29 in fascia.
So i have been through all the diagrams i can get hold of seeing what effects the multifunction from ecm side only brake switch by the looks of things.
Checked fuses again and i can disable the brake lights by removing maxi fuse 48 in the engine fuse box. What i really need is a multifunction wiring diagram as i still have no idea which pins do what on the unit and for some reason none of the plugs from it want to disconnect.
Gonna have a search in a minute for a how to on removal/replacement of j519.

Any input greatly appreciated

Crasher
09-04-2013, 06:27 PM
PM me your email

Columbusracing
09-04-2013, 09:49 PM
pm sent cheers crasher

Crasher
09-04-2013, 11:37 PM
I will do it tomorrow.

Crasher
11-04-2013, 10:45 PM
OK, on the case...

Columbusracing
12-04-2013, 12:39 AM
cheers fella :)

Columbusracing
13-05-2013, 07:56 PM
Well havin had a little play i have gotten no where :) so far got the pin outs for the rear of the j519 - with the multiplug that feeds the brake light switch into the unit unplugged brake lights still on with ignition on.
I i unplug the outlets to the rear lights from the j519 the lights go out so the fault is at the j519 end :)
Can't for the life of me work out from vw current flow diagrams what actually feeds the j519 and powers it directly. Its always at the top of the page in the diagrams which means its the source of power from my understanding.
The lights function as intended when ignition is off and are on constantly when the ignition is on so when the ignition is powered up something is powering the lights - failed j519??
but why do the lights work on the switch if the ignition is off?
If the relay or whatever is inside the box was constantly actuated surely they would be on all the time and not function correctly with the ignition off.
If anyone can help clear up my confusion a little would be greatly appreciated
thanks

Crasher
13-05-2013, 11:48 PM
The J519 is a body control module that controls most things and is considered un-repairable internally so they provide no details.

Columbusracing
14-05-2013, 06:42 PM
cheers Crasher i've ordered a second hand one with the same part number found it quite amusing that tps will not give you part numbers and its a sackable offence if they do :)
Recoding do i just copy the really long code i have at the moment and write to the replacement module. Sure it will be in the forum somewhere i'll have a search in a moment.
cheers

Crasher
14-05-2013, 10:35 PM
Yes, cut and paste the long coding value over.

Columbusracing
20-05-2013, 01:19 PM
Ta da massive failure !!!!
swapped over the unit coding was pretty easy (thanks crasher) but brake lights still on with ignition so there must be something back feeding the j519 with ignition.
Haven't really been going about this the right way - gonna go and read all the circuit diagrams again map out everything which has a brake pedal signal and go over it all again.

Didn't get round to posting until i had had another little play - so i can turn brake lights off by pulling all the fuses i have mentioned before and also by pulling the larger ecu plug K. Tried back probing the brake position switch and brake light switch terminals at the ecu and got nothing.
So now going through all terminals on the k plug to try and identify a possible problem.
Got to check the esp ecu aswell :)
good times

Columbusracing
20-05-2013, 06:10 PM
Can also shut the lights off if i pull the plug to the steering column module(one under the cowlings) or plug G on the j519 . If you take out power to the steering column module it seems to shut everything down.

The only one that still gives me other functions is pulling plug K on the ecu. From what i can see there is only 1 connection from j519 to plug K and that is through the brake light switch ( not brake position switch). With ignition on there is no voltage on this wire unless the brake switch is actuated. With the switch disconnected i have nothing on the brake switch wiring but the lights are still on.

So if that has no connection to the j519 how is it getting a signal to power the lights up?

Could this be a fault in the steering column module (can't remember the j number) or a short off the ecu? But the only thing that should power up the brake lights is the brake light switch pin on j519 connector E pin 2. With connector E detached i still have brake lights on.

Unplugging the abs controller (pump) makes no difference to the problem at all.

What size voltage would cause the j519 to switch would it have to be 12v or would a short on a 5v sensor feed be enough?

I can't see where to go next at the moment getting in lost in a sea of terminal numbers and wiring diagrams - i've got about 40 pages of fuse layouts and diagrams/current flow diagrams. Been

Crasher
20-05-2013, 11:40 PM
There is a connector block in the plenum chamber under a cover below the wiper motor that has 12 positions and is green or blue, there is one of each. Disconnect these one at a time. When the lights turn off, make a note of some of the wire colours and positions of the relevant colour plug.

Columbusracing
21-05-2013, 01:00 PM
The connectors block which affects the lights is in position 5 has a green plug and 12 pins as follows:
Pin1 - brown/blue
Pin 2 - black/grey
Pin 3 - yellow/green
Pin 4 - red/grey
Pin 5 - blue/white
Pin 6 - grey/blue
Pin 7 - orange/black - can??
Pin 8 - orange/black - can??
Pin 9 - yellow
Pin 10 - brown
Pin 11 - red/white
Pin 12 - green/white

cheers for the help crasher :)

Crasher
21-05-2013, 02:48 PM
That is T12c and not what I expected to happen, I expected unplugging T12b to do that which we now known is the blue plug.

Pin 1 - brown/blue - Accelerator position sender 2
Pin 2 - black/grey - Accelerator position sender 2
Pin 3 - yellow/green - Accelerator position sender
Pin 4 - red/grey - Accelerator position sender
Pin 5 - blue/white - Accelerator position sender
Pin 6 - grey/blue - Accelerator position sender 2
Pin 7 - orange/black – CAN high
Pin 8 - orange/brown – CAN low
Pin 9 – yellow - Radiator outlet coolant temperature sender
Pin 10 – brown - Radiator outlet coolant temperature sender
Pin 11 – white/red - clutch pedal position hall sender
Pin 12 – white/green - brake pedal switch

The next step will be to release the white/red from socket 11 and plug the connector back in and see if the lights stay off.

Columbusracing
23-05-2013, 10:29 PM
will have a go at that asap will have to dig out my terminal tools and have a play thanks once again crasher for all the help. Covering for someone at work at the moment so have no spare time. Will hopefully get around to this before the weekend if not shortly after.
cheers

Columbusracing
29-05-2013, 03:40 PM
Well the can wiring turns off the brake lights :(
Load tested with my hook from the ecu terminals to the plenum and all wiring passed the test.
Looks to me like the engine is ecu is badgered what does anyone else think?

We've had a dry joint which caused low voltage on one of the 5v feeds to the accelerator pedal which was bridged due to being "non repairable" so one feed supplys to both 5v on the acc pedal. Thats worked fine for ages now we have this error which i can see no way of circumventing gonna have to revert the loom to how it was and replace the ecu.

Any help greatly appreciated as per usual.

Found code - 02071 - no signal communication in central electronics

Got a broken connector on the acc position sensor in the t12c the terminal just fell into 2 when removing so got some spares on the way from TPS.

Columbusracing
29-05-2013, 05:22 PM
We're looking to find a replacement ECU, the current ones part number is 03C 906 056 BA and i've been advised that this has been superceeded with the 03C 997 056 M. Could anyone advise which other ECU's would be suitable as replacements as I'm having trouble locating an exact match and don't fancy forking out 700 quid for a new one.

Crasher
29-05-2013, 07:21 PM
Disconnecting which CAN wire turned them off, 7 or 8?

Columbusracing
29-05-2013, 08:08 PM
Both did each wire was removed for testing then replaced to test the next one.
Been reading online manuals from Bosch on can bus and still unsure how it works.
Thanks for poppin in crasher

Can low was removed first my mate who owns the car did this testing and didn't fully reassemble the connector every time when I had a look the can terminals were very loose so possibly can low did not reconnect properly when can high wire was tested?

Crasher
30-05-2013, 12:46 AM
Its late, prod me tomorrow when I am sober.

Doctle Odd
30-05-2013, 01:07 AM
It's usually me this late that's:alcoholic
Its late, prod me tomorrow when I am sober.

Columbusracing
30-05-2013, 02:55 PM
hello i rechecked after repairing the damaged connector and both can high and can low turn the lights off
Ignition off resistance between can high and low = 66 ohms
Engine running can high 2.6v
can low 2.2 v
I was told spec should be can high 2.5 - 3.75 and low 1.25 and 2.5 so apparently they are in spec??

Crasher
30-05-2013, 06:20 PM
The CAN is turning the lights on by its digital signal to the on-board supply unit but as to WHY it is doing this I am not sure. Next I would try disconnecting the white/green at 12c/12 and see if the lights remain on. If the do, the ECU sending out a digital command to turn on the brake lights for some bizarre reason. Did I ever ask to to use a diagnostic system to observe the switch logic binary codes to see what the ECU sees their status to be? I cannot remember the group codes but I have one in tomorrow and I will find out what they are.

Columbusracing
03-06-2013, 11:10 PM
12c being the green plug still? have already had the green/white wire out which had no effect on the brake lights condition.
Binary switching?
Will have a look at the live data for the engine ecu again when i get chance.
cheers crasher

Crasher
03-06-2013, 11:31 PM
I think the brake light switch/brake pedal switch binary bit display is in Measuring Blocks 066, zone 3 and is a row of zero's possibly eight, so 00000000 with no pedals depressed, where the value would be 00000011 with the brake pedal depressed and 00000111 with the brake and clutch pedal depressed.

Columbusracing
07-06-2013, 07:21 PM
well in block 66-2 switch positions 1 i have (ignition on)
00000110 brake pedal released
00000111 brake pedal depressed
Clutch pedal doesn't seem to effect switch positions 1 or 2 (66-4) so what does it have that is always on in bits 6 and 7. clutch position and brake position?
Brake lights are on with ignition but checking in live data shows the brake lights are off with ignition on and the switch operates as normal even though its not effecting the constant brake lights.

Just checked 66-2 again and its the same at the end but currently showing
11000110 brake pedal released and 11000111 brake lights depressed what has switched on i haven't done anything? if look at 08-1 brake pedal status its non operational at all times.
Selected gear always stays at zero - broken park neutral switch?

Getting a little confused with binary now but according to live data the brake light switch is operating as normal but the brake lights are always on
Have the following log from today
VCDS Version: Release 11.11.5
Data version: 20121222

Friday,07,June,2013,19:17:49:27189

Chassis Type: 1K0
Scan: 01 03 09 15 16 17 19 25 42 44 46 52 56

VIN: WVWZZZ1KZ4W124278 Mileage: 154690km/96119miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine Labels: 03C-906-056-BAG.lbl
Part No SW: 03C 997 056 M HW: Hardware No
Component: MED9.5.10 G00 9265
Revision: 00000000 Serial number: VWZ7Z0D9531196
Coding: 0002032
Shop #: WSC 00389 210 91447
VCID: 377B64784627B1A0D06

No fault code found.
Readiness: 1110 0101

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No: 1K0 907 379 K
Component: ESP FRONT MK60 0103
Coding: 0019073
Shop #: WSC 01279 785 00200
VCID: 3A7D7D4C7535ACC82F8

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 3C0-937-049-23-M.lbl
Part No SW: 1K0 937 049 S HW: 1K0 937 049 S*
Component: Bordnetz-SG 1.0 H30 0704
Revision: 00H30000 Serial number: 00000001067490
Coding: 008D0F0600041800001400001400000000
Shop #: WSC 12345 123 12345
VCID: 3F8B0C586E1789E0186

Component: Fehler Lin-Slave 01

1 Fault Found:
02071 - Local Databus
004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1K0-909-605.lbl
Part No SW: 1K0 909 605 A HW: 1K0 909 605 A
Component: 0M AIRBAG VW8 022 0500
Revision: 04022000 Serial number: 0033FD0ADFL7
Coding: 0012365
Shop #: WSC 01268 785 00200
VCID: 2A5D4D0C85951C485F8

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
Part No SW: 1K0 953 549 A HW: 1K0 953 549 A
Component: Lenksäulenmodul 012 0030
Coding: 0000022
Shop #: WSC 01279 785 00200
VCID: 30695F64A349669891C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No: 1K0 920 950 K
Component: KOMBIINSTRUMENT VDD 3556
Coding: 0001401
Shop #: WSC 00358 067 08055
VCID: 30695F64A349669891C

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 1K0-907-530-V1.clb
Part No SW: 1K0 907 530 C HW: 1K0 907 951
Component: Gateway H08 0080
Revision: 08 Serial number: 26001043090131
Coding: 3D0F0140070003
Shop #: WSC 01279 785 00200
VCID: 275BB43896872120406

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No: 1K0 920 950 K
Component: IMMO 3556
Shop #: WSC 00000 000 00000
VCID: 30695F64A349669891C

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN1.lbl
Part No: 1K0 959 701 E
Component: Tuersteuergeraet 09 0116
Coding: 0000052
Shop #: WSC 01279 785 00200
VCID: 30695F64A349669891C

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb
Part No: 1K2 909 144 F
Component: EPS_ZFLS Kl.0 1301
Shop #: WSC 00000 000 00000
VCID: 2F6B5C18BE777960886

1 Fault Found:
00778 - Steering Angle Sensor (G85)
000 - -

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1K0-959-433-MIN.clb
Part No: 1K0 959 433 C
Component: KSG 0201
Coding: 00E802087F2D8404085B0100
Shop #: WSC 01279 785 00200
VCID: 30695F64A349669891C

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN1.lbl
Part No: 1K0 959 702 E
Component: Tuersteuergeraet 09 0116
Coding: 0000052
Shop #: WSC 01279 785 00200
VCID: 316F5A60A8436F909E2

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No: 1K0 035 186 J
Component: Radio BNO 0016
Coding: 0020202
Shop #: WSC 01279 785 00200
VCID: 2D574610B47B0B70BAA

No fault code found.

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

gonna have to check the ecu pins again on anything brake/clutch related to see if i work out what causing the switching.

cheers

Crasher
08-06-2013, 10:07 PM
The data is saying the brake pedal is depressed but so is the clutch pedal, with NO pedals depressed it should say 00000000 so 00000110 says the clutch AND the brake pedal are depressed but the brake pedal is only depressed on one of its two contacts as brake and clutch pedal depressed it should say 00000111, the 00000110 says something is wrong with the brake pedal switch and clutch pedal switch if both are in the up position. Disconnect the plugs from the brake and clutch pedal switches and see what the last three bits register, the whole block should be 00000000.

Columbusracing
09-06-2013, 06:33 PM
Cheers fella will give that a go monday eve when i get a chance thanks again.

Columbusracing
09-06-2013, 08:04 PM
clutch switch wiring is in the engine bay right couldn't see any plugs or electronics on the pedal side when i had a look when playing on friday.
cheers

Crasher
09-06-2013, 11:10 PM
There is something silly but simple going on here, does the car have any aftermarket devices of any kind?

Columbusracing
10-06-2013, 09:02 AM
It had aftermarket Hids which i removed when i found the 02071 code and read the special notes on vag com. There is also a sub fitted might disconnect that aswell when i get a chance. Other than that just some of those cheap tat raceland coilovers and a set of wheels.
Hopefully get a chance to play with it again this evening.
thanks crasher

Is the steering angle code mainly down to needing to be driven in a straight line after a battery disconnection?

Columbusracing
10-06-2013, 10:43 AM
Just checked with brake switch and clutch switch disconnected i still have 00000110.
I was under the impression that without the clutch switch it wouldn't start but i appear to have no problem.

Crasher
10-06-2013, 06:08 PM
I think you have given me the clue I was looking for, I suspected something was cooked and it is possibly the engine ECU because of the illegal HID lights. You are going to have to track down another ECU and plug it in to see if the lights stay out. If they do, you will need to get the car to VW to have the replacement ECU coded in. Some independents can do this but not many, I can't do some of them.

The steering warning light MAY go out after a good drive and some slow manoeuvring around a car part turning the car from hard full lock to hard full lock and suddenly the light goes out and the steering stops feeling odd.

Columbusracing
19-06-2013, 01:52 AM
Hi crasher thanks for the help as per normal :)
Trying to source an ecu can i use any vw ecu for a BAG engine code or does the vw number and bosch number have to be exact?
So if the existing ecu is 03c 906 056 ba bosch 0 261 s02 070 do i have to find another identical ecu or can one with the last two characters changed ie
VW TOURAN 1.6 FSI 2003-2005 ENGINE ECU 03C906056F - BAG (http://www.ebay.co.uk/itm/VW-TOURAN-1-6-FSI-2003-2005-ENGINE-ECU-03C906056F-BAG-/110991420486?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item19d79aac46)http://pics.ebaystatic.com/aw/pics/s.gif
any help with this confusion would be great might get the car driveable again then

Crasher
19-06-2013, 01:18 PM
To replace a 03C 906 056 BA you can use a 03C 997 056 H or 03C 997 056 M. As the 03C 906 056 BA superseded 03C 906 056 B it may be possible to use one of these but I am not sure and they are rare anyway. 03C 906 056 F is programmed specifically for very early 2004 Touran BAG 6 speed EU4 emissions only.

Columbusracing
19-06-2013, 11:03 PM
ta very much :)

Columbusracing
08-07-2013, 04:51 PM
Does anyone on here happen to have any of the following ecus available for sale:
03C 906 056 BA
03C 997 056 H
03C 997 056 M
If so drop me a pm that would be grand
cheers

Guest 2
08-07-2013, 04:58 PM
03C 906 056 BA VW GOLF MK5 1.6 FSI BAG ENGINE CONTROL UNIT ECU 0 261 S02 070 | eBay (http://www.ebay.co.uk/itm/03C-906-056-BA-VW-GOLF-MK5-1-6-FSI-BAG-ENGINE-CONTROL-UNIT-ECU-0-261-S02-070-/360662781908?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item53f92d4fd4)

Motosteuergärete. 03C 906 056 BA Oder 03C 997 056 M | eBay (http://www.ebay.de/itm/Motosteuergarete-03C-906-056-BA-Oder-03C-997-056-M-/181171153796?pt=DE_Autoteile&hash=item2a2ea46b84)

Only two on eBay that I could find.

You could look at the breaking ad's but you'd need to check the engine number etc.

Columbusracing
08-07-2013, 06:57 PM
cheers chris didn't have either of them on my watchlists :)
Have you ever bought parts from germany would language settings need to be changed or anything special when getting it coded to the vehicle?
Thanks again

Guest 2
08-07-2013, 07:08 PM
I've bought most of my retrofit stuff from eBay DE and haven't had any problems.

I'm guessing if the part number is the same then I shouldn't see any problem but I'll let Crasher confirm/disagree with that.

Columbusracing
08-07-2013, 11:02 PM
cheers chris that ecu might be the ticket with the low budget we've got.

Crasher oh fountain of knowledge can you confirm whether or not there would be any probs using a german ecu?

Crasher
08-07-2013, 11:13 PM
Non whatsoever, all engines speak the same language...That ECU is ideal but a little expensive but if it is all you can find then you don't have much choice, lets just hope I have got this right!

mattegel
14-07-2013, 12:22 PM
My fix might help you.

My brake lights were staying on and if I stabbed the brake pedal quickly I could get them to go out while the engine was off. So it lead me to believe it was a vacuum issue. So I went to the junk yard and tried to get a brake booster but didn't have the tool to get the booster shaft off the back of the pedal. So I just took the master cylinder because it started to rain really hard. Put in the used master cylinder and it didn't fix it. Pulled the master cylinder back out and inspected the plunger that pushes the master cylinder. I found that to be loose and could be pulled out and set into a position that made it stick out further which would cause it to make the brake lights come on. I twisted the plunger until it was as far back as it would go which it felt like it had a cog or gear behind it that the plunger needed to be placed in the right spot to make sure it was as far back as it could go and then bent the three small tin silver tabs that is supposed to hold it in place and put it back together and it works fine now.



Root Cause:
Three silver tin flimsy tabs that hold the plunger back behind the master cylinder bend out and allow the plunger to move out further then it should where it gets hung up and sticks out far enough to cause the brake lights to come on.

Resolution:
#1. Replaced brake booster
#2. Adjust the plunger on the brake booster behind the master cylinder by twisting it until you feel it go back as far as it can go (Probably only need to adjust it a 1/4 turn at most). Bend the three silver tabs back to hold it in place. Done.
_

Crasher
14-07-2013, 07:53 PM
Sorry old boy but in post five you can see it makes no difference with the brake pedal switch completely unplugged.

Guest 2
27-07-2013, 07:46 AM
Any update OP?


Sent from my iPhone using Tapatalk

Columbusracing
28-07-2013, 05:27 PM
ballsed up bidding on the german ecu so trying to get one for less then 300 through breakers at the moment :)

Columbusracing
05-08-2013, 03:07 PM
found a matching ecu on the bay at the weekend just paid for it got to wait for arrival to test and see if it cures the fault. Nice and cheap aswell £36 posted bargin :)

Columbusracing
15-08-2013, 03:24 PM
Well that didn't work at all brake lights still on with ignition and binary still the same. Any other ideas the only other thing that seems to turn them off is the steering column control unit bet they aren't cheap either.

Crasher
15-08-2013, 06:21 PM
But I thought the ECU being disconcerted turned the lights off? If it does but a new ECU is the same and the binary block last digits are 00 it does not make sense or there is an input turning them on that you have missed but I thought you went through everything.

Columbusracing
19-08-2013, 10:44 PM
hi crasher i thought i went through everything aswell :(
Gonna start a fresh and check everything again has to be something i missed.
will keep this updated just got to get time to look at it again.

Columbusracing
28-08-2013, 06:16 PM
Well after spending a good few hours re examining things me and my mate have temporarily sorted the brake light issue :)
Was going through all the fuses again and discovered that fuse 7 in the engine bay box (feed for brake position sensor and clutch switch was blown even though i had replaced it before. Tried another fuse and had another mate stood at the back of the car brake lights went off for a second before the fuse blew.
So we connected up a fuse saver circuit breaker and the five amp trip was going in an instant when it did stay on briefly a wisp of smoke from the rear of the engine bay could be seen.
So i disconnected the clutch switch again and breaker doesn't trip - wiring to the switch looks good we seem to have a short in the clutch switch.
Will have a better go at checking that tomorrow i am off for a celebratory pint :)

20vtiny
26-02-2014, 11:42 PM
Thank you very,very much for posting the fix for this problem. you are a legend for sticking with this problem until the bitter end. I hope you get this message as I cant send a private message because I am a Newby. Well done to Crasher for his encyclopaedic knowledge of this topic. How does he fit all that information in his head. Well done chaps.

Crasher
27-02-2014, 06:23 PM
How does he fit all that information in his head. Well done chaps.

I don't, I keep it in a glass at the side of my bed, the same one as with me teeth in.