Few faults thrown up by VCDS

[5aq1b]

Alrighty, 1st post guys so take it easy

I've got a 05 plate Mk5 Golf, TDi 140bhp, remapped to 175bhp.

Over the past year or so I've had a few problems with the car, with the engine light on. About 8 mths ago I had a problem with the EGR which was throwing up the code:

19559 motor for intake manifold flap v157 malfunction P3103.

Ever since the "Emissions workshop" message and the engine light has been on, i've noticed a considerable drop in power from the car. I got the EGR replaced around 2 months ago and was hoping that this would fix it but the mechanic told me that due to the fact that I had ran it so long without replacing the EGR, i now need a throttle body for it. The engine light still won't go off. Is this possible as i don't wanna get ripped off.

The car also goes into limp mode on the motorway if I give it a good bashing. Bloody struggles to overtake 18 wheelers when in limp mode.

Also the mechanic told me there's a fan fault. The fan's not letting my engine warm up. Not a big problem in the summer but can cause burnout to the engine in the winter. Couple hundred quid for 2 fans ive been told.


I decided to get my car scanned by vag-com yesterday and here's what it threw up.

-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-016-BKD.lbl
Part No SW: 03G 906 016 FM HW: 028 101 190 3 begin_of_the_skype_highlighting 028 101 190 3 end_of_the_skype_highlighting
Component: R4 2,0L EDC 0000SG 6179
Revision: 12345678 Serial number: VWZ7Z0D1261505
Coding: 0000072
Shop #: WSC 66565 257 00032

4 Faults Found:
19558 - Motor for Intake Manifold Flap (V157): No Signal
P3102 - 000 - -
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.31 V
Bin. Bits: 00000100
Torque: 0.0 Nm
Torque: 354.0 Nm

19557 - Motor for Intake Manifold Flap (V157): Open or Short to Ground
P3101 - 000 - -
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.31 V
Bin. Bits: 00000100
Torque: 0.0 Nm
Torque: 354.0 Nm

17075 - Fan 1 Control Circuit: Short to GND
P0691 - 000 - -
Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.31 V
Bin. Bits: 00000100
Temperature: 81.9°C
Duty Cycle: 9.6 %

16618 - Boost Pressure Regulation: Limit Exceeded (Overboost Condition)
P0234 - 000 - -
Freeze Frame:
RPM: 2268 /min
Torque: 148.0 Nm
Speed: 119.0 km/h
Load: 32.2 %
Voltage: 13.98 V
Bin. Bits: 11000000
Absolute Pres.: 1744.2 mbar
Absolute Pres.: 2193.0 mbar

Readiness: 1 2 0 0 0


I'm hoping someone can help - and if the symptoms i've had with the car match the faults found on the log above, and if theres any cost-saving solution to the problems?

Appreciate any help.

[Eshrules]

all of these faults, I presume, have arisen following the remap?

did the remapper perform a diagnostic test prior to completing his work?

[5aq1b]

all of these faults, I presume, have arisen following the remap?

did the remapper perform a diagnostic test prior to completing his work?

I'm not sure if he ran a diagnostics mate. The remap was done around April 2008 so it's been a couple years, and yes, the problems have occurred after the remap.

The engine light and EGR fault didnt appear until around August 2009 so a good 16 mths until after the remap

[martin1810]

You need a new mechanic. This is a well known problem. The antishudder valve normally fails and jams which blows the fuse which stops the fan working as well. This is all part of the egr so you have to replace that. The overboost may be a different problem but can be related. Change the egr, fix the fuse, reset codes and see what codes come back....

[5aq1b]

You need a new mechanic. This is a well known problem. The antishuder valve normally fails and jams which blows the fuse which stops the fan working as well. This is all part of the egr so you have to replace that. The overboost may be a different problem but can be related. Change the egr, fix the fuse reset codes and see what codes come back....

Hi Thanks for the reply mate. The EGR's been replaced a couple months back.

And wht do you mean by "fix fuse reset codes". How do I fix them mate?

[zollaf]

i think he means fit a new fuse, and clear the codes.

[5aq1b]

i think he means fit a new fuse, and clear the codes.

cheers mate, theres a halfords down the road from my work. MY cars at home right now. Can i pick one of these fuses up from there?

[5aq1b]

You need a new mechanic. This is a well known problem. The antishudder valve normally fails and jams which blows the fuse which stops the fan working as well. This is all part of the egr so you have to replace that. The overboost may be a different problem but can be related. Change the egr, fix the fuse, reset codes and see what codes come back....

Alright mate, i've fitted a new fuse. Do i have to clear the codes to notice a difference? No access to VAGCOM for a couple days.

[5aq1b]

any ideas guys? thanks

[martin1810]

You need the codes cleared. Run for a few days and then code read again. That way you can see what codes are current. I think you may have turbo vanes sticking but you need the new read to give you a clue.