2008 1.9tdi bxe stalling

[dean.st]

and we're back. The garage thinks the g28 sensor is faulty so i have a warranty exchange one on order. He said that there is no reading from g28 when trying to start but when it kicks in the car starts. Then when the car stalls it is still reading g28 for a few seconds until it vanishes.

The error can't be cleared at the moment as it is.

One thing he did say was that the ecu may need updating too. I have a t6 work van which has had 4 or 5 remaps to solve many issues that it has had.

I'm thinking rather than update/reflash the same map i may aswell get a stage 1 remap done. Am i correct in thinking a upgraded remap will do the same as a standard remap will in terms of clearing stubborn fault storage?

[dean.st]

one more question. Should i have 2 live 5v (approx) wires at the crank sensor plug with the ignition switched on? Just like the cam sensor has.

[dean.st]

Today i fitted another new crank sensor. It has made no difference.

It takes a while to start after a good few cranks.

However i have now cleared the engine speed faults showinv and the EML has gone off.

I still have the heater plug light flashing and the esp ligbt is stuck on permanent on amber.

No codes are showing on my handheld reader.

I'll be speaking to an electrical engineer ref possible ecu error tomorrow.

Anyone have any more things that this starting issue is caused by?

[Crasher]

You need a proper code read, if the ESP light is on there may be a non OBDII code stored in the engine ECU and the ABS ECU; replacing the engine ECU is the last resort, in the last 40 years of dealing with engine management systems I have had to replace only a handful of ECU’s. Also a new ECU is not a plug and play process, it can get very stressful to do correctly.

[dean.st]

I spoke to the ecu guy today and he said unlikely to be the ecu itself. So i went and got the codes read again. They are as follows


00802 engine speed sensor g28 no signal p0322

05661 GL w plug for cylinder 4 open circuit p161d

01314 engine control module read trouble codes

00576 terminal 15 electrical problem in circuit - intermittent

00883 ignition switch (d) terminal s electrical problem in circuit - intermittent

00884 ignition switch (d) terminal X electrical problem in circuit - intermittent

01744 ignition switch terminal p (d) electrical problem in circuit - intermittent

00885 ignition switch (d) terminal 50 electrical problem in circuit - intermittent

It was suggested to test the relevant pins between the ecu and cam sensor but he wasn't sure which they would be without a wiring diagram.

It would seem that the engine can't get a signal from the crank sensor so it gets it from the cam sensor instead which causes the prolonged starting time.

Can some advise which pins at the ecu i need to test and exactly how to read it. I have a multimeter so can follow the instructions.

[Crasher]

Did you fit a new ignition switch? They are a big problem on the Golf 5 platform, we fit lots.

[monty9120]

Allot of fault codes are there because of failed starts ie taking out ignition when it’s not managed to start

The speed sensor is an issue as they won’t rev properly when in neutral and if it doesn’t read you moving may cause more issues

I know you bridged the relay is there a fuel cut off on these that’s dodgy ie car had a small bump


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[dean.st]

Further update. I fitted a new genuine ignition switch and it made no difference. I then went to fit new glow plugs and the last one is just spinning!!!!!

This effing car is fighting me every step of the way.

So once i figure out how to remove the glow plug i then need to figure out why the ecu cannot see the crank sensor to start the car.

[Roverfan]

one more question. Should i have 2 live 5v (approx) wires at the crank sensor plug with the ignition switched on? Just like the cam sensor has.

I am not a pro but I hope you don't mind if I offer my two pence.

1 and 3 are usually positive and ground, middle one being signal wire which can have voltage on a pull down cam/crank sensors. So two 5v's can be good. Outer ones must be positive and ground at all times ign on.

.
Finally yesterday i did some readings from the g40 & g28 plugs. The g40 was fine with 2 x 4.9v and a 0v.

The g28 however has the following readings with the ignition on.

pin 1black/red 0v
pin 2 purple 4.9v
pin 3 brown/blue 0v

Going by mk6 wiring diagrams, this shows a problem. The 5v reference wire is open circuit, perhaps intermittently. Assumption being the wiring is configured same as mk6 - signal wire pin2.

Since a range of sensors are not effected it shows the problem lies in the 5v ref wire going to the g28 crank sensor. I would trace that wire back through the loom to the point of damage or break

[Roverfan]

I found some online wiring diagrams for bxe engine. There is a difference with the mk6. According to the diagram the wires are not spliced and all three run direct through to the ecu.

So although it could still be a break, the wires will want checking at the ecu connector. The diagram is showing the concerned ecu connector pins as T60 pins 57, 58, 42 should be easy to verify being same colour.