Hi Guys,

 

Problems started when I had intake flap off to clean out heavy deposits of gunk,

Refitted and started for a few weeks then it started to crank twice start and die after a second or 3, scanned with VCDS and came up intake short/ open circuit, so I replaced with used part off eBay and problem went away for a few weeks.

 

The engine doesn't shudder when turned off as much as it does with intake flap plug disconnected.

 

I've had the ECU connector off and the wiring loom seems ok from what I've probed, no breaks to intake flap pin 3+4 which are purple/grey purple/ yellow cables or shorts from these to other cables.

Did notice battery voltage (13v) from pins 1+2 and what seems like regulated 12v (12.6v)on pins 3+4

 

Every time I plug in VCDS the car starts ok for reasons unknown.

 

Taking the flap apart the motor spins when 12v applied and gear teeth are intact, i guess its the microcontroller in the cover or hall effect sensor that has went bad but even though it was spotless inside cover and usual culprit is oil ingress on these parts.

 

I do get these fault codes:

 

Address 19: CAN Gateway        Labels:. 7N0-907-530-V1.clb

   Part No SW: 7N0 907 530     HW: 1K0 907 951

   Component: J533  Gateway   H27 5603 

   Revision:   H27       Serial number: 231010F2001249

   Coding: E9A07F0600020200002303

   Shop #: WSC 73430 790 00999

   VCID: 6DD17CB37491F7FB10-8038

 

2 Faults Found:

012545 - Motor for Intake Manifold Flap (V157)

               P3101 - 000 - Open or Short to Ground - Intermittent

             Freeze Frame:

                    Fault Status: 00100000

                    Fault Priority: 0

                    Fault Frequency: 1

                    Reset counter: 255

                    Time Indication: 0

 

             Freeze Frame:

                    RPM: 0 /min

                    Speed: 0.0 km/h

                    Load: 0.0 %

                    Voltage: 5.09 V

                    Bin. Bits: 00101100

                    Torque: 0.0 Nm

                    Torque: 351.4 Nm

 

012547 - Motor for Intake Manifold Flap (V157)

               P3103 - 000 - Malfunction - Intermittent

             Freeze Frame:

                    Fault Status: 00100000

                    Fault Priority: 0

                    Fault Frequency: 4

                    Reset counter: 255

                    Time Indication: 0

 

             Freeze Frame:

                    RPM: 0 /min

                    Speed: 0.0 km/h

                    Load: 0.0 %

                    Voltage: 9.20 V

                    Bin. Bits: 11001110

                    Torque: 0.0 Nm

                    Torque: 351.4 Nm

 

Readiness: 1 2 0 0 0

 

1 Fault Found:

01314 - Engine Control Module

            004 - No Signal/Communication - Intermittent

             Freeze Frame:

                    Fault Status: 00110100

                    Fault Priority: 2

                    Fault Frequency: 1

                    Reset counter: 146

                    Mileage: 222775 km

                    Time Indication: 0

                    Date: 2018.04.20

                    Time: 17:49:48

 

Checked grounds from battery -ve to strut and behind LHS headlight, were a bit corroded but shiny now.

New battery fitted and when cranking its turning over nice and fast.

 

Sometimes glow plug light will flash when cranking.

 

I can hear lift pump from tank prime when turning key to on position.

 

When the car is running I've gave the loom a tug here and there and no issues.

 

I've ordered a new cam and crank sensor even though when graphing their data through VCDS advanced measurements (See attached) the cam speed has some dead spots when blipping the accelerator.

The problem then would be it would start and die 3-5 times then start and run fine, idles fine, no smoke, seems it has as much of it's original 105hp as is expected.

Now its at the point to get it started cold I need to disconnect the battery negative wait and reconnect otherwise it will just crank/ crank 3 times fire up and die after 2 seconds.

Then once engine is up to temp and trying to start it will just crank until I press in the accelerator pedal then it starts.

Tried disconnecting the intake flap when cold and car will run and cut out after I try and take off.

Engine is a 1.9TDI BXE on the timing belt cover but BKC when looking at engine label in VCDS.

Issue is car is only worth £1000 on we buy any car and second hand car market is still nuts with 2011 1.9 golfs looking 4-5K....

 

Also ordered a K-line commander to get SKC to see if disabling the immobiliser helps. Although it sees all 3 keys when looking at VCDS and will identify when in ignition.

 

 

Now even after replacing the motor control flap with a new part I'm still getting a passive/sporatic fault being logged with the motor.