2009 1.9 tdi bxe electrical issues no glowplug no mil

[nakpipe]

First of all i dont have vcds. I do have electrical skills and experience though.
The Jetta has the dreaded cutting out / no glowplug / no mil / red steering issue. Thanks to some detailed threads on here, i have found a broken wire on T94/39 its purple /red. If I manipulate it at a certain point i can hear the glowplug relay pull in, as well as a valve ? energising near the top of the engine. There isnt much detail in the haynes manual, so if a kind soul could provide a diagram that would be much appreciated

Cheers

Nakpipe

[Crasher]

What is the VIN? Without knowing if any codes are stored you are going to struggle.

[Crasher]

T94/39 is the sensor 1 in the accelerator pedal

[nakpipe]

Thank you Crasher much appreciated. So far 6 lightweight wires have suffered damage from some type of reaction

[Crasher]

Whereabouts? Pictures?

[nakpipe]

Hello Crasher, apologies for the delay in answering your question. The thin wires at the t94 plug have suffered from i would suspect is some from of overheating possibly due to increased resistance and or just the fraility of using very light cable in the midst of a busy loom. Not much cable segregation in play. However t94/18 is a pain at the moment, keeps dropping out, have you experienced the terminal/crimp within the the t94 giving problems ? I will try and look for info on uploading a photo or two. Cheers

[Crasher]

Those pins are a bloody nuisance. The plug will have a few unused pins, these can be carefully extracted after carefully dismantling the plug and transred to the ne position and the wire pushed in. The VAG method is to cut the wire, waterproof crimp seal on a new yellow repair wire 000 979 026 E EA for Gold plated) and push this through which is easier but ugly. I have had to replace a few complete plug (3C0 906 385 @ £37.15) and doing it the factory way is tedious delicate work but making 94 or 68 wires all yellow would be a sketch.

[nakpipe]

Thanks for the info Crasher, A wee bit of progress to report. Supplies arrived from the intranet and T94 /18 is now fixed , no longer dropping out. A bit fiddly to get the terminal out (a female pin) but using a small jewellers screwdriver it eventually gave.
There are no spare terminals in the ecu, so now on the dreaded repair wires. The ecu carries a rubber version of the pin in empty terminals.
The bugger is the old terminal looked fine, tested spot on with the DVM, but obviously started failing under load.
Thanks again

[Crasher]

A new plug comes with all new terminals.

[nakpipe]

Yes, if i was doing this again....i would cetainly would purchase a new plug. Currently (npi) I am reading 0.7v on T94/86 red / black and 2.3v on T94/87 black red. In addition still missing the glow plug and the eml. Although repairs to t94/18 has rectified the dropping out issues. T94/49 b/g is fine but not switching the relay ! The relay is fine and work with a temp earth installed. Great fun !