Multiple fault codes after car gradually loses power and drive

[DMitch16]

Short description of events: Dropped someone off at work noticing that car seemed to be "holding back" on the way. Drove back through a village at 30 mph and engine warning light (the glow plug generic one) came on. Car starts to slow down despite foot remaining in same place on accelerator eventually not moving more than 5mph so I pulled over and switched off but beforehand noting that the idle revs were just over 1000 rpm (normally bang on 800 - unerringly consistent too for a car with 156K on the clock). Waited for a few minutes and tried to restart, warning light still flashing, car turns over but does not fire. This is repeated 4 more times with no joy on starting and exhaust gas warning light illuminates also during this but may be as a result of the failed starts. Turned off and waited another few minutes and decided to try once more before calling recovery service. Warnings lights are off this time and car starts! Got her back home and scanned with VCDS to find lots of codes in different modules - some I already knew about.

Here are the scan results:

Address 01: Engine Labels: 03G-906-018-BMN.clb
Part No SW: 03G 906 018 AS HW: 03G 906 018 AS
Component: R4 2.0l PPD1.2 G 9971
Revision: --H42--- Serial number: VWZCZ000000000
Coding: 0000078
Shop #: WSC 00338 210 91434
VCID: 76CD3B910156C891443-8023


4 Faults Found:
012600 - Intake Manifold Runner Control
P3138 - 006 - Regulation Deviation - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 5
Fault Frequency: 7
Reset counter: 40
Mileage: 248349 km
Time Indication: 0
Date: 2015.05.16
Time: 10:19:58


Freeze Frame:
RPM: 1824 /min
Torque: 136.0 Nm
Speed: 25.0 km/h
Mass Air / Rev.: 654.0 mg/str
Mass Air / Rev.: 670.4 mg/str
Lambda: -27.3 %
Text: Kein Messwert verfuegbar


005214 - Mass Air Flow during Regeneration too Low
P145E - 006 - - Intermittent
Freeze Frame:
Fault Status: 00000001
Fault Priority: 5
Fault Frequency: 1
Reset counter: 40
Mileage: 248347 km
Time Indication: 0
Date: 2015.05.16
Time: 10:05:51


Freeze Frame:
RPM: 1856 /min
Torque: 40.0 Nm
Speed: 40.0 km/h
0.00 %
11.31 %
Mass Air / Rev.: 337.9 mg/str
Mass Air / Rev.: 528.6 mg/str


001602 - Sensor Reference Voltage A: Circuit
P0642 - 007 - Low - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100010
Fault Priority: 5
Fault Frequency: 10
Reset counter: 40
Mileage: 248348 km
Time Indication: 0
Date: 2015.05.16
Time: 10:08:28


Freeze Frame:
RPM: 0 /min
Torque: 48.0 Nm
Speed: 0.0 km/h
Voltage: 1.95 V
Hex Value: 0x0002
Voltage: 11.75 V
Voltage: 11.98 V


000802 - Engine Speed Sensor (G28)
P0322 - 006 - No Signal - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100001
Fault Priority: 5
Fault Frequency: 10
Reset counter: 40
Mileage: 248348 km
Time Indication: 0
Date: 2015.05.16
Time: 10:08:28


Freeze Frame:
RPM: 0 /min
Torque: 48.0 Nm
Speed: 0.0 km/h
Bin. Bits: 00000001
Bin. Bits: 01000011
(no units): 11.0
Angle: 0.0 °


Readiness: N/A

Address 09: Cent. Elect. Labels: 3C0-937-049-23-H.lbl
Part No SW: 3C0 937 049 AE HW: 3C0 937 049 AE
Component: Bordnetz-SG H52 2002
Revision: 00H52000 Serial number: 00000006648006
Coding: E9800F0700041A00470A00000F00000000395D435C0001
Shop #: WSC 05311 123 12345
VCID: 6CF919F94F1A0241A27-8039


Subsystem 1 - Part No: 3C2 955 119 B Labels: 1KX-955-119.CLB
Component: Wischer 220107 022 0601
Coding: 00046997
Shop #: WSC 05311


Subsystem 2 - Part No: 1K0 955 559 AH Labels: 1K0-955-559-AG.CLB
Component: RLS 030410 054 0403
Coding: 00471213
Shop #: WSC 05311


3 Faults Found:
02071 - Local Databus
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 27
Mileage: 247200 km
Time Indication: 0
Date: 2015.05.04
Time: 15:37:00


Freeze Frame:
OFF
Voltage: 12.50 V
OFF
ON
OFF
OFF
OFF


01334 - Door Control Module; Rear Right (J389)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 30
Mileage: 247252 km
Time Indication: 0
Date: 2015.05.05
Time: 08:42:00


Freeze Frame:
OFF
Voltage: 12.60 V
OFF
ON
OFF
OFF
OFF


01520 - Rain and Light Recognition Sensor (G397)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 2
Fault Frequency: 2
Reset counter: 36
Mileage: 247200 km
Time Indication: 0
Date: 2015.05.04
Time: 15:37:00


Freeze Frame:
OFF
Voltage: 12.50 V
OFF
ON
OFF
OFF
OFF

Address 19: CAN Gateway Labels: 3C0-907-530-V1.clb
Part No SW: 3C0 907 530 C HW: 3C0 907 951 A
Component: Gateway 007 0040
Revision: 00007000 Serial number: 0700C07131022D
Coding: 3FFD0C04E61003
Shop #: WSC 05311 000 00000
VCID: 216738CDF8581F29411-8074


1 Fault Found:
01334 - Door Control Module; Rear Right (J389)
004 - No Signal/Communication - Intermittent
Freeze Frame:
Fault Status: 00100100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 29
Mileage: 247252 km
Time Indication: 0
Date: 2015.05.05
Time: 08:42:36

Address 56: Radio Labels: 1K0-035-1xx-56.lbl
Part No: 1K0 035 186 T
Component: Radio GR0 020 0023
Revision: 0002006S Serial number: VWZ2Z2G2225358
Coding: 0042402
Shop #: WSC 05314 000 00000
VCID: 3753F69546DC71999F5-8062


1 Fault Found:
00857 - CD Changer Unit (R41)
014 - Defective - Intermittent

Address 77: Telephone Labels: 3C0-035-730.lbl
Part No SW: 7L6 035 730 HW: 7L6 035 730
Component: Telefon 2209
Revision: 00011000 Serial number: 0000000008709
Coding: 0020035
Shop #: WSC 05311 000 00000
VCID: 6BFB1AE54A140579ABD-803E


1 Fault Found:
00992 - Consumption Cut-Off Active
000 - - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 3

Fault Frequency: 3
Reset counter: 61
Mileage: 248348 km
Time Indication: 0
Date: 2015.05.16
Time: 10:10:22

All those dated 16.05.2015 are related to this mornings loss of drive.

Any ideas as to where to start? Battery?? Faulty electrics somewhere?? Any measuring blocks in VCDS to look at battery capacity etc.?

Car running fine at present, back to its 800 rev consistent idle and revs freely with no "pull back". New alternator only 15,000 miles ago but ORIGINAL battery.

Thanks.

[DMitch16]

Just to add...I have a vacuum operated swirl flap mechanism and therefore will renew the tubing, MT2 vacuum solenoid switch (looks like a smaller N75 solenoid valve) and runner actuator to cure the Inlet Manifold Runner control error. The EGR valve and throttle body was cleaned around 30,000 miles ago but not the inlet manifold. I'm going to do this again along with cleaning the manifold and entire intercooler / pipework as there is a build up of oil in the intercooler system from the crankcase vent (cam cover to pre turbo intake pipe) that has reached the exit side of the intercooler itself now and probably up the throttle intake pipe mixing in with the exhaust gas entering the EGR (before it goes into the throttle body then manifold). The electric motor operating the EGR valve will get a once over or replacement to ensure the valve is operating smoothly.

[RichardSEL]

Yikes! Original battery They're good those OEM factory-fitted Molls, but not that good. Mine started delivering less power (and not holding charge) after five years on my '06MY. Went on to do another winter's service jump starting neighbour's Mondeo. Change out for a Bosch S5008, 77AHC. Many eBay suppliers that'll deliver to your door, it's a cut-throat business so expect to pay no more than £80 inc all inc delivery.

Can't see from your Autoscan what your mileage is but current faults are mixed up with previous ones. So, after battery changeout, go into each module and clear all faults. And then see what comes back.

Any help?

[martin1810]

Manifold intake flaps have failed. get it checked quick. if one breaks and goes in the engine. eek!!

[DMitch16]

Update: Plastic intake pipe had split underneath just after the MAF sensor thus a certain volume of air was bypassing it. Fault code "005214 -*Mass Air Flow*during Regeneration too Low"*therefore solved and replacement pipe fitted.

[DMitch16]

Manifold intake flaps have failed. get it checked quick. if one breaks and goes in the engine. eek!!

Thanks Martin, I had suspected some fouling of the inlet manifold flaps and at over 150K the plastic can't be in the best of condition. The fault seems to occur every day so the manifold is coming off pronto!

[RichardSEL]

Update: Plastic intake pipe had split underneath just after the MAF sensor thus a certain volume of air was bypassing it. Fault code "005214 -*Mass Air Flow*during Regeneration too Low"*therefore solved and replacement pipe fitted.

Interesting for a pipe split. The fault's only shown in your Autoscan the once

[DMitch16]

Interesting for a pipe split. The fault's only shown in your Autoscan the once

The spring clip wasn't on properly either and the pipe had slipped of at the flange. I am thinking now that the code was for the pipe coming off not the split (which I may not have discovered for a while if the pipe had not come off). MAF code has not returned.

[DMitch16]

Latest update: All codes cleared and engine ran for a few minutes. Engine then threw the two codes relating to 001602 - Sensor Reference Voltage A: Circuit P0642 - 007 - Low - Intermittent - MIL ON and 000802 - Engine Speed Sensor (G28)*P0322 - 006 - No Signal - Intermittent - again!

These two seemed to be linked and are on the same loom as the V157 flap motor which has thrown up numerous codes in the past (but not this time).

I'm stumped (electrics not my strong point). Any suggestions?

[vespa]

New batteries are super discounted at ECP this week. Maybe worth a look.