So a few weeks ago I bought a cheap, high mileage (180k) Octavia Mk2 Pre FL 1.9 TDI, which I intend to keep running until it gets too expensive to fix. I'm hoping to bring it back to as good condition as possible while I have it, as a bit of a hobby as much as anything else. This thread is a bit of a personal log for my sake, but also I hope to gain a bit of help from all the experts on this forum.

 

Here's how it looks at the moment:

 

 

Needs a clean! It's been cleaned today and looks a lot better, just waiting for some daylight to take some more pics. 

 

Onto the faults, I did a VCDS scan and got this back:

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Chassis Type: 1Z (1K0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 55 56 62 69 72 76

VIN: TMBGS21ZX52085796   Mileage: 292680km-181862miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: Malfunction 0010
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
55-Headlight Range -- Status: OK 0000
56-Radio -- Status: Malfunction 1010
62-Door, Rear Left -- Status: Malfunction 0010
69-Trailer -- Status: OK 0000
72-Door, Rear Right -- Status: Malfunction 0010
76-Park Assist -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 03G-906-016-BKC.lbl
   Part No SW: 03G 906 016 K    HW: 028 101 223 7
   Component: R4 1,9L EDC G000SG  7002  
   Revision: 12345678    Serial number: SKZ7Z0E2929726
   Coding: 0000071
   Shop #: WSC 73430 790 00000
   VCID: 2B4D11EF1305C55A9AD2091-807E

3 Faults Found:
16785 - EGR System 
            P0401 - 000 - Insufficient Flow - Intermittent
             Freeze Frame:
                    RPM: 1974 /min
                    Torque: 41.5 Nm
                    Speed: 50.0 km/h
                    Load: 16.9 %
                    Duty Cycle: 14.7 %
                    Mass Air / Rev.: 255.0 mg/str
                    Mass Air / Rev.: 540.0 mg/str

17055 - Cylinder 1 Glow Plug Circuit (Q10) 
            P0671 - 000 - Electrical Fault
             Freeze Frame:
                    RPM: 0 /min
                    Torque: 114.7 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 12.16 V
                    Bin. Bits: 00001100
                    Temperature: 6.3°C
                    Bin. Bits: 00110000

17058 - Cylinder 4 Glow Plug Circuit (Q13) 
            P0674 - 000 - Electrical Fault
             Freeze Frame:
                    RPM: 0 /min
                    Torque: 114.7 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 12.16 V
                    Bin. Bits: 00001100
                    Temperature: 6.3°C
                    Bin. Bits: 00110000

Readiness: 1 1 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK70.lbl
   Part No: 1K0 907 379 P
   Component: ASR FRONT MK70      0105  
   Coding: 0000641
   Shop #: WSC 73430 790 00000
   VCID: 3F9555BFF77D49FA261A6D1-806A

No fault code found.

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Address 08: Auto HVAC        Labels: 1K0-907-044.lbl
   Part No: 1Z0 907 044 J
   Component: ClimatronicPQ35 084 0305  
   Shop #: WSC 00000 000 00000
   VCID: 3D692FB7FD715BEA3406779-8068

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3C0-937-049-23-H.lbl
   Part No SW: 1K0 937 049 N    HW: 1K0 937 049 N*
   Component: Bordnetz-SG     H34 0803  
   Revision: 00H34000    Serial number: 00000003091283
   Coding: 418A8F120004140000110D000000000000087F065C
   Shop #: WSC 24000 576 14151
   VCID: 3A6324ABEC5F6CD2112454D-806E

   Subsystem 1 - Part No: 1Z2 955 119 A  Labels: 1KX-955-119.CLB
   Component: Wischer SK351  012  0401  
   Coding: 00065525
   Shop #: WSC 24000  

   Subsystem 2 - Part No: 1K0 955 559 M  Labels: 1K0-955-559-AF.CLB
   Component: RegenLichtSens 005  0605  
   Coding: 00217125
   Shop #: WSC 24000  

No fault code found.

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Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 L    HW: 1K0 909 605 L
   Component: Q4 AIRBAG VW8   025 0700  
   Revision: 08025000    Serial number: 0038CD07A97Q  
   Coding: 0020788
   Shop #: WSC 73430 790 00000
   VCID: 35793797C54183AAFC769F9-8060

   Subsystem 1 - Serial number: 6332MSME21027D09 

   Subsystem 2 - Serial number: 6342MSME1F207D09 

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 G    HW: 1K0 953 549 G
   Component: Lenksäulenmodul 021 0050  
   Coding: 0002042
   Shop #: WSC 73430 790 00000
   VCID: 367B309BD84788B2F57C80D-8062

   Subsystem 1 - Part No: XXXXXXXXXXX 
   Component: Lenkradmodul    007 0050

1 Fault Found:
00888 - Wiper Switch for Intermittent Operation (E22) 
            014 - Defective - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No: 1Z0 920 941 D
   Component: KOMBIINSTRUMENT VD1 0918  
   Coding: 0007401
   Shop #: WSC 24000 576 85313
   VCID: 38673EA3D2537EC2E750BE5-806C

1 Fault Found:
00003 - Control Module 
            014 - Defective

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 1K0-907-530-V1.clb
   Part No SW: 1K0 907 530 E    HW: 1K0 907 951 
   Component: Gateway         H11 0110  
   Revision: 11          Serial number: 2900105303068B
   Coding: 7D3F4740072303
   Shop #: WSC 73430 790 00000
   VCID: 2941EBE719F9D74A68FE139-807C

3 Faults Found:
00470 - Company Comfort Databus in Single Wire 
            012 - Electrical Fault in Circuit
             Freeze Frame:
                    Fault Status: 01101100
                    Fault Priority: 3
                    Fault Frequency: 254
                    Reset counter: 143
                    Mileage: 292562 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 21:05:14

01305 - Databus for Infotainment 
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 1
                    Fault Frequency: 254
                    Reset counter: 143
                    Mileage: 292562 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 21:05:15

01304 - Radio 
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 2
                    Fault Frequency: 254
                    Reset counter: 183
                    Mileage: 292613 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 21:51:55


-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No: 1Z0 920 941 D
   Component: IMMO            VD1 0918  
   Shop #: WSC 00000 000 00000
   VCID: 38673EA3D2537EC2E750BE5-806C

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MIN1.lbl
   Part No: 1T0 959 701 
   Component: Tuersteuergeraet 09 0166  
   Coding: 0000118
   Shop #: WSC 73430 790 00000
   VCID: 74FFCA938EBBDAA20BE82A5-8020

2 Faults Found:
00470 - Company Comfort Databus in Single Wire 
            011 - Open Circuit
00943 - Heated Exterior Mirror; Driver Side (Z4) 
            012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-14x-44.clb
   Part No: 1K2 909 144 H
   Component: EPS_ZFLS Kl.2       1502  
   Shop #: WSC 00000 000 00000
   VCID: 317103873129AF8AA08ECB9-8064

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1K0-959-433-MIN.clb
   Part No: 1K0 959 433 AK
   Component:    KSG              0401  
   Coding: 18D002407F2D8505481F861004C8
   Shop #: WSC 73430 790 00000
   VCID: 79E1FBA7A9D9A7CA58DEE39-802C

   Subsystem 5 - Part No: 1Z0 951 171 
   Component: Innenraumueberw.008 4801  
   Coding: 00000000
   Shop #: WSC 00000  

   Subsystem 6 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HORN H02 1301

   Subsystem 7 - Component:       NGS n.mounted     

1 Fault Found:
00470 - Company Comfort Databus in Single Wire 
            012 - Electrical Fault in Circuit

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MIN1.lbl
   Part No: 1T0 959 702 
   Component: Tuersteuergeraet 09 0166  
   Coding: 0000118
   Shop #: WSC 73430 790 00000
   VCID: 75F9F79785C1C3AA3CF6DF9-8020

1 Fault Found:
00470 - Company Comfort Databus in Single Wire 
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 55: Headlight Range        Labels: 1T0-907-357.lbl
   Part No: 1T0 907 357 
   Component: Dynamische LWR      0002  
   Coding: 0000001
   Shop #: WSC 24000 576 14151
   VCID: 74FFCA938EBBDAA20BE82A5-8020

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio
Cannot be reached

-------------------------------------------------------------------------------
Address 62: Door, Rear Left        Labels: 1K0-959-703-GEN1.lbl
   Part No: 1K0 959 703 B
   Component: Tuersteuergeraet 06 0219  
   Coding: 0000048
   Shop #: WSC 73430 790 00000
   VCID: 2F7505FF271DB97AB6BADD1-807A

1 Fault Found:
00470 - Company Comfort Databus in Single Wire 
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 69: Trailer        Labels: 8P0-907-383.lbl
   Part No SW: 8P0 907 383     HW: 8P0 907 383 
   Component: ANHAENGERELEKTR H01 0010  
   Coding: 0000001
   Shop #: WSC 73430 790 00000
   VCID: 76FBF09B98C7C8B235FCC0D-8022

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right        Labels: 1K0-959-704-GEN1.lbl
   Part No: 1K0 959 704 B
   Component: Tuersteuergeraet 06 0219  
   Coding: 0000048
   Shop #: WSC 73430 790 00000
   VCID: 307706833A23A682AF80C65-8064

1 Fault Found:
00470 - Company Comfort Databus in Single Wire 
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: 1Z0-919-283.lbl
   Part No SW: 1Z0 919 283 B    HW: 1Z0 919 283 B
   Component: Parkhilfe 4-Kan H04 0020  
   Coding: 0010001
   Shop #: WSC 73430 790 00000
   VCID: 3D692FB7FD715BEA3406779-8068

No fault code found.

End-------------------------(Elapsed Time: 02:00)--------------------------

To summarise:

01-Engine:
	1.	EGR blocked
	2.	Glow plug (cylinder 1) electrical fault
	3.	Glow plug (cylinder 4) electrical fault

16-Steering wheel:
	1.	Wiper switch for intermittent operation defective

17- Instruments:
	1.	Control module defective

19- CAN Gateway:
	1.	Company Comfort Databus in Single Wire, electrical fault
	2.	Databus for Infotainment no signal
	3.	Radio no signal – intermittent

42-Door elect, driver:
	1.	Company Comfort Databus in Single Wire, open circuit
	2.	Heated exterior mirror, driver side, electrical fault

46-Central conv.:
	1.	Company Comfort Databus in Single Wire, electrical fault in circuit

52-Door elect, pass:
	1.	Company Comfort Databus in Single Wire, open circuit

56-Radio
	1.	Cannot be reached

62-Door, rear left:
	1.	Company Comfort Databus in Single Wire, open circuit

72-Door, rear right:
	1.	Company Comfort Databus in Single Wire, open circuit

Working through the faults:

1. EGR: My current plan is to get the car remapped (hopefully this won't expose any serious faults and kill something major!) and at the same time get the EGR mapped out. I can then remove it at my leisure, without the annoying EML being on.
2. Glow plugs: I've tested them with a multi-meter and thankfully it's just a couple of dead glow plugs, so I'll be replacing them with some from ECP when I get chance. Access to them is okay so I won't bother replacing all four. 
3. Everything else: seems to be mostly related to a break in one of the CAN bus wires - any one got any ideas how I can find out where? The scan only returned "open circuit" on four of the modules - the doors. Would this suggest the fault is something to do with the central convenience module (I think the doors plug into this?). I've ordered a new CCM as mine doesn't have any options on the maxidot (mine's an AK and I've bought and AR) so I'll fit that and see if it fixes anything.

 

Note: the radio faults above are because I've changed the Audience (non mp3) for an aftermarket head unit, as I couldn't cope without an AUX input. It's supposed to be CAN bus friendly but I haven't put much effort into setting it up yet, so hopefully I can make it play a little nicer. I've bought a new CAN Gateway as I anticipated battery drain issues, so far this hasn't been a problem but the car hasn't been left sitting for more than 24 hours. I'll fit it when I fit the CCM. 

Edited 8 June, 201610 yr by TobyMTDI

Do you still have the car ??