MK5 Golf 1.9 TDI (BKC) Power loss/Limp mode and Esp light displays

[VWGOLFTDIGTI]

Hi All,
Finally got round to registering, though i've been on this forum for some time for hints tips etc.
I could really do with some help on this, it has me baffled and im struggling to work it out.
As mentioned i have a 1.9 TDI (105bhp) BKC engine Mk5 Golf, it feels underpowered, as ive driven several of these mk5 1.9 tdi's and i know what sort of power it has. Though the turbo does kick in, it doesnt feel quiet enough.
When the car is driven to around 60-70mph, it normally goes into limp mode. Sometimes it can happen before reaching 60-70mph, but on average it normally occurs at the speed. Also, the ESP light comes on shortly after. Although, i have had the ESP light come on before it goes into limp mode aswell. Switching the car off and on normally gets the car to reset both limp/esp light, but within 5 minutes it reoccurs.
I must also mention i have an issue with my brakestoo, after a few quick pumps it goes hard. (Ill get back to that below)

I have plugged in VAG COM nothing significant showed up (unless ive overlooked something, the vag com reading is below), so i set about trying to eliminate all possibilities.

I started with the vacuum pump, which was weak and i had hoped would resolve both the brakesand the turbo issue, thus i replaced it and unfortunately it did neither.
Brakesfault is now diagnosed as independent and likely the brake servo, which im not looking forward to doing/getting done.

So i left the brakesfor abit and thought id attempt to address the turbo/limp mode issue.
Luckily, i had done a friend a favour, he owns a 1.9 TDI (BKC) Audi A32005, and i basically used his car as a donor to essentially apply trial and error with his parts.
I tried the following.
1. MAP Sensor
2. Boost Pressure Sensor
3. Not sure what its called, i think its called the vacuum solenoid valve (Black block)
4. As mentioned the Vacuum pump was replaced
5. Boost pipe

None of the above resolved the issue, so then i looked at the actuator for the Turbo, and it didnt seem to have free movement, nor a full range of movement, was convinced it can only be that, so i went out and replaced the turbo itself as i was just getting fed up.
Drove it and made no difference. Same issue.

There are no air leaks that were found. I just want to make it clear, im by no means a mechanic, the turbo was changed by a garage as i dont have access to a ramp, anything that can be replaced without a need for a ramp i tend to have a go at myself.

Today, i sprayed some Wynns EGR Cleaner into the air intake, but made no difference. I have noticed a bit of black smoke when the car is revved hard, but nothing out of the ordinary.

EGR replacement next? or is it pointless? Has anyone experienced the same issue, i would love to hear from you. I promise if i do get to the bottom of this, i shall update this post. There is nothing like reading a thread that has no end.


I bought vag com recently and i have not really got to grips with it properly yet.

Vag com reading is below. Yep, i need to change the glow plugs, not got round to doing that yet, just want to resolve this issue first.

Monday,09,March,2015,16:54:35:52368
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 14.10.1.1 (x64)
Data version: 20150130





Mileage: 194790km-121036mi Repair Order:








Mileage: 194790km-121036miles



Address 01: Engine Labels: 03G-906-016-BKC.lbl
Part No SW: 03G 906 016 B HW: 028 101 147 8
Component: R4 1,9L EDC G000SG 5645
Revision: 12345678 Serial number: VWZ7Z0D9742950
Coding: 0000071
Shop #: WSC 00000 028 00001
VCID: 224DB17EFD036131584-8077


5 Faults Found:
18049 - Please check DTC Memory of A/C Controller
P1641 - 000 -
Freeze Frame:
RPM: 882 /min
Torque: 30.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.36 V
Bin. Bits: 00001100
Temperature: 55.8*C
(no units): 0.0


17055 - Cylinder 1 Glow Plug Circuit (Q10)
P0671 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 46.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.44 V
Bin. Bits: 00001000
Temperature: 12.6*C
Bin. Bits: 10110000


17056 - Cylinder 2 Glow Plug Circuit (Q11)
P0672 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 46.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.44 V
Bin. Bits: 00001000
Temperature: 12.6*C
Bin. Bits: 10110000


17057 - Cylinder 3 Glow Plug Circuit (Q12)
P0673 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 46.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.44 V
Bin. Bits: 00001000
Temperature: 12.6*C
Bin. Bits: 10110000


17058 - Cylinder 4 Glow Plug Circuit (Q13)
P0674 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 46.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.44 V
Bin. Bits: 00001000
Temperature: 12.6*C
Bin. Bits: 10110000


Readiness: 0 0 1 1 1


Address 03: ABS BrakesLabels: 1K0-907-379-MK60-F.lbl
Part No: 1K0 907 379 K
Component: ESP FRONT MK60 0103
Coding: 0021121
Shop #: WSC 01279 785 00200
VCID: 3A7D691E759309F1604-806F


2 Faults Found:
00668 - Supply Voltage Terminal 30
002 - Lower Limit Exceeded - Intermittent
01314 - Engine Control Module
013 - Check DTC Memory - Intermittent


-
Address 08: Auto HVAC Labels: 1K0-820-047.lbl
Part No: 1K0 820 047 CR
Component: Climatic PQ35 081 0404
Shop #: WSC 00000 000 00000
VCID: 76E5BD2E010BAD9144C-8023


1 Fault Found:
00819 - High Pressure Sensor (G65)
009 - Open or Short to Ground



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: 00030000 Serial number: 00000000641176
Coding: E4890F0600041800001400001400000000
Shop #: WSC 00000 000 00000
VCID: 3F8B180A6EB12CD957A-806A


Subsystem 1 - Part No: 1K2 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:
01064 - Terminal 58d; Interior Dimming
012 - Electrical Fault in Circuit - Intermittent


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 1K0-909-605.lbl
Part No SW: 1K0 909 605 D HW: 1K0 909 605 D
Component: 02 AIRBAG VW8 022 0600
Revision: 05022000 Serial number: 0033JD0BWK9O
Coding: 0012338
Shop #: WSC 01268 785 00200
VCID: 2D575242B4DDAE49F56-8078


Subsystem 1 - Serial number: 6332MSME364F7D02


Subsystem 2 - Serial number: 6342MSME08366302


Subsystem 3 - Serial number: 6351HSME224B0002


Subsystem 4 - Serial number: 6361HSME0B437101


No fault code found.


-------------------------------------------------------------------------------
Address 16: Steeringwheel 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: 30694B36A3EFC3A1DE0-8065


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
Part No: 1K0 920 950 L
Component: KOMBIINSTRUMENT VDD 3556
Coding: 0001401
Shop #: WSC 00581 210 64475
VCID: 316F4E32A8E5CAA9D1E-8064


1 Fault Found:
01314 - Engine Control Module
004 - No Signal/Communication - Intermittent



-------------------------------------------------------------------------------
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: 316F4E32A8E5CAA9D1E-8064


1 Fault Found:
00933 - Electric Window Motor; Passenger Side (V14
005 - No or Incorrect Basic Setting / Adaptation - Intermittent


-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No: 1K0 035 186 J
Component: Radio BNO 0016
Coding: 0040400
Shop #: WSC 01279 785 00200
VCID: 2D575242B4DDAE49F56-8078


2 Faults Found:
00875 - Treble Speaker Front Right (R22)
011 - Open Circuit
00871 - Bass Speaker Front Right (R23)
011 - Open Circuit


-------------------------------------------------------------------------------
Address 7D: Aux. Heat Labels: 1K0-963-235.lbl
Part No SW: 1K0 963 235 D HW: 1K0 963 235 D
Component: PTC-Element 0404
Revision: 00700000 Serial number:
Shop #: WSC 00000 000 00000
VCID: 2C515F468FC7A741E28-8079


1 Fault Found:
00361 - Heater Element for Auxiliary Heater (Z35)
014 - Defective

(I have deleted some of the readings because i cant post this, as it exceeds the word limit

[Doctle Odd]

You need to save the codes then delete them, give it a day or 2 and rescan, I'd imagine a lot of the codes are old.

[VWGOLFTDIGTI]

You need to save the codes then delete them, give it a day or 2 and rescan, I'd imagine a lot of the codes are old.

Hi thank you very much for the reply, i did exactly what you said and those are the codes that came up. I cleared all codes, then rescanned a day later (after taking it for a drive)

[VWGOLFTDIGTI]

I did another scan but this time i did it differently, i took the car for a drive, then once it went into limp mode, i plugged in the diagnostic, which gave an interesting reading. (P0299 see below)

7 Faults Found:
18049 - Please check DTC Memory of A/C Controller
P1641 - 000 -
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.24 V
Bin. Bits: 00001100
Temperature: 60.3°C
(no units): 144.0


17911 - Load Signal from Alternator Term. DF
P1503 - 000 - Implausible Signal
Freeze Frame:
RPM: 882 /min
Torque: 30.0 Nm
Speed: 3.0 km/h
Load: 0.0 %
Voltage: 14.14 V
Bin. Bits: 00001111
Load: 0.0 %
(no units): 1.0


16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
RPM: 3066 /min
Torque: 248.0 Nm
Speed: 76.0 km/h
Load: 100.0 %
Voltage: 14.21 V
Bin. Bits: 00001000
Absolute Pres.: 2029.8 mbar
Absolute Pres.: 1570.8 mbar


17055 - Cylinder 1 Glow Plug Circuit (Q10)
P0671 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 52.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.21 V
Bin. Bits: 00001000
Temperature: 9.9°C
Bin. Bits: 10110000


17056 - Cylinder 2 Glow Plug Circuit (Q11)
P0672 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 52.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.21 V
Bin. Bits: 00001000
Temperature: 9.9°C
Bin. Bits: 10110000


17057 - Cylinder 3 Glow Plug Circuit (Q12)
P0673 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 52.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.21 V
Bin. Bits: 00001000
Temperature: 9.9°C
Bin. Bits: 10110000


17058 - Cylinder 4 Glow Plug Circuit (Q13)
P0674 - 000 - Electrical Fault
Freeze Frame:
RPM: 882 /min
Torque: 52.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 14.21 V
Bin. Bits: 00001000
Temperature: 9.9°C
Bin. Bits: 10110000

[VWGOLFTDIGTI]

Just to update you all, i got the servo replaced (twice!) and still no luck
Any help would be much appreciated.
Guy that replaced the servo has booked it in again, to replace the vacuum pump again and the vacuum hose.
I will update with the outcome.

[Doctle Odd]

Seems like you need 4 glow plugs ans have the turbo/n75 checked. I'd start by checking all vacuum pipes and boost hoses. Replaced servo why?

[zollaf]

ok, not read the whole thread so excuse me if i have missed something, but you are seriously beating about the bush here. the brake pedal goes hard after a few presses and it lacks power, so you have a vacuum leak somewhere, so start by replacing all the little vacuum pipes to the turbo, egr and asv and it should cure the fault for the price of 3 metres of vacuum pipe. vacuum pumps, servos, jees, someone has seen you coming and isn't very busy right now.
but yes, you do need new glow plgs as doc says, or it could be the fuse or relay gone.

[VWGOLFTDIGTI]

ok, not read the whole thread so excuse me if i have missed something, but you are seriously beating about the bush here. the brake pedal goes hard after a few presses and it lacks power, so you have a vacuum leak somewhere, so start by replacing all the little vacuum pipes to the turbo, egr and asv and it should cure the fault for the price of 3 metres of vacuum pipe. vacuum pumps, servos, jees, someone has seen you coming and isn't very busy right now.
but yes, you do need new glow plgs as doc says, or it could be the fuse or relay gone.

yeah the glow plugs issue is the last of my worries, its not causing any apparent problems nor any warning lights, so ill change it in due course.
As for the mechanics leading me on lol, no. He changed the servo twice because the initial servo he put in had an air leak. I was not charged twice for it. And the servo in this model is one heck of a job, so for him to do it twice and has said he will replace my vacuum pump and pipes for free, i think he wants to get to the bottom of it just as much as i do. The chap who fitted the initial vacuum pump was someone else. The one who is currently dealing with it is a good friend. Who is charging me peanuts.

[Big dyl]

Did you resolve the problem ? Just wondering if you did a calibration on all your newly fitted components with vag com ? Maybe that was the problem new devices installed / replaced requires vag comm to calibrate on to ecu.Otherwise your car wont see your new compnent and ecu will still be in safe mode.