Stage 2 Tune made my GTI 1.8T go bonkers! Please help

   #1  

30secondgti

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Hello to all,

I am really hoping someone out there might have some knowledge or ideas about what is happening to my car. I've already gotten some pretty decent advice from some 'car minds', but we've still not been able to fix the problem.

MAIN PROBLEM: CAR RUNS ROUGH BUT DOES NOT TRIGGER AND FAULT CODES WITH STOCK SOFTWARE/ PROGRAM. 3 ATTEMPTS TO RUN 'STAGE 2 SOFTWARE' HAS RESULTED IN CONTINUED FAULT CODES AND LIMP MODE. (please see below)

2002 VW GTI 1.8T AWP

Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))

Modifications: Stage 2 Tune, cold air intake, 2 or 2.5" down pipe, high flow muffler (I'm sorry I can't remember what model or type), NGK Iridium IX spark plugs

See below first Auto-Scan done on July 07, 2014

Code:
Monday,07,July,2014,15:01:49:50875
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0 (x64)
Data version: 20140212

VIN: 9BWDE21J7240xxxxx   Mileage: 144860km/90011miles


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

-------------------------------------------------------------------------------
Address 01: Engine Labels: 06A-906-032-AWP.lbl
Part No: 06A 906 032 HS
Component: 1.8L R4/5VT G 0008
Coding: 07500
Shop #: WSC 00000
VCID: 76EDE6CC520186AEB1B-513C
3VWSE69M62M193142 VWZ7Z0B4932131

2 Faults Found:
17705 - Pressure Drop between Turbo and Throttle Valve (check D.V.!)
P1297 - 35-10 - - Intermittent
17579 - Angle Sensor 2 for Throttle Actuator (G188) Implausible Signal
P1171 - 35-10 - - Intermittent
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ASR.lbl
Part No: 1C0 907 379 K
Component: ASR FRONT MK60 0103
Coding: 0021505
Shop #: WSC 00000 785 00200
VCID: 32651ADCAEE9DA8E5D3-513C

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 A
Component: 1M AIRBAG VW51 02 0004
Coding: 12621
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5102

1 Fault Found:
00591 - Seat Belt Switch; Driver (E24)
32-10 - Resistance Too High - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 806 J
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 07332
Shop #: WSC 00000
VCID: 2E5D0EACEAD1FE6E39B-5102
9BWDE21J7240xxxxx VWZ7Z0B5281213

1 Fault Found:
01177 - Engine Control Unit
64-10 - Not Currently Testable - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00000
VCID: F0E150D4B065289EEB7-5120

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 1J Komfortgerát HLO 0003
Coding: 00064
Shop #: WSC 00000
VCID: 37732BC8158B3FA66AD-4B00

Subsystem 1 - Part No: 1C1959801A
Component: 1J Tõrsteuer.FS KLO 0002

Subsystem 2 - Part No: 1C1959802A
Component: 1J Tõrsteuer.BF KLO 0002

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 E
Component: Radio ZSW 0010
Coding: 00031
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5120

No fault code found.

End ---------------------------------------------------------------------

See below 2nd Auto-Scan done on July 10, 2014

Code:
Thursday,10,July,2014,19:14:08:50875
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0 (x64)
Data version: 20140212

VIN: 9BWDE21J7240xxxxx   Mileage: 144890km/90030miles

Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

-------------------------------------------------------------------------------
Address 01: Engine Labels: 06A-906-032-AWP.lbl
Part No: 06A 906 032 HS
Component: 1.8L R4/5VT G 0008
Coding: 07500
Shop #: WSC 00000
VCID: 76EDE6CC520186AEB1B-513C
3VWSE69M62M193142 VWZ7Z0B4932131

2 Faults Found:
17705 - Pressure Drop between Turbo and Throttle Valve (check D.V.!)
P1297 - 35-00 -
17972 - Throttle Actuator (J338)
P1564 - 35-10 - Under-Voltage during Basic Setting - Intermittent
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ASR.lbl
Part No: 1C0 907 379 K
Component: ASR FRONT MK60 0103
Coding: 0021505
Shop #: WSC 00000 785 00200
VCID: 32651ADCAEE9DA8E5D3-513C

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 A
Component: 1M AIRBAG VW51 02 0004
Coding: 12621
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5102

1 Fault Found:
00591 - Seat Belt Switch; Driver (E24)
32-10 - Resistance Too High - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 806 J
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 07332
Shop #: WSC 00000
VCID: 2E5D0EACEAD1FE6E39B-5120
9BWDE21J7240xxxxx VWZ7Z0B5281213

1 Fault Found:
01177 - Engine Control Unit
64-10 - Not Currently Testable - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00000
VCID: F0E150D4B065289EEB7-5102

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 1J Komfortgerát HLO 0003
Coding: 00064
Shop #: WSC 00000
VCID: 37732BC8158B3FA66AD-4B18

Subsystem 1 - Part No: 1C1959801A
Component: 1J Tõrsteuer.FS KLO 0002

Subsystem 2 - Part No: 1C1959802A
Component: 1J Tõrsteuer.BF KLO 0002

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 E
Component: Radio ZSW 0010
Coding: 00031
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5120

No fault code found.

End ---------------------------------------------------------------------

Both Auto-scan's are the same except for the second fault code in the "Engine" section.

This is the third ECU/ ECM that we've installed in the last 10 months. The first ecu was a "06A 906 032 HS", the 2nd was "06A 906 032 LP" and the current ecu in the car is a new/ used "06A 906 032 HS" from a nearby auto wrecker.

The current "06A 906 032 HS" ecu was working decently with an unmolested stock program/ settings. The adaptation went semi smoothly. It was running a little rough, quite a bit of vibrations when idling. None the less it worked for around 3 months without any fault codes or limp mode happening. I decided to be a little over exuberant and put the Stage 2 tune back in. After and hour or two of driving the car with the new stage 2 tune, the EPC & traction control cluster lights came back on and the car went into limp mode. I cleared all the codes and got about 4 days of driving out of it until the car went back into limp mode with the corresponding cluster lights. For some reason this car does not like tunes or the ecu to be tampered with. Is this acceptable or is there a solution to this problem?
I bought this car with a stage 2 tune and wanted to go fast. Now its broken down
The only conclusion I can come up with is that the stage 2 tune is running the engine harder/ hotter and in turn the wiring and circuits are heating up causing all sorts of problems.
Also...before installing the second ECU/ ECM, we installed a new Accelerator Module as the fault code read;17579 - Angle Sensor 2 for Throttle Actuator (G188) Implausible Signal P1171 - 35-10 - - Intermittent. The new Accelerator Module is part# 6Q1 721 503 M. It seems with the new Accelerator Module installed; nothing has changed and the fault code keeps appearing. (keep in mind the above fault codes only appear after installing the stage 2 tune)

Any help would be more then appreciated. This has been driving me crazy. I've been walking and taking the bus on and off for the last 10 or so months. lol....

Thanks





After reverting back to a Stock flash (July 27), 2 days later of driving the car the below fault codes came back. I was under the impression that if you save the stock flash file (which we did) and revert back to stock, that the car's ecu is wiped clean and the cars ecu is stock. Maybe not the case?

thanks.

Code:
Tuesday,29,July,2014,20:26:03:50875
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0 (x64)
Data version: 20140212


--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
76

VIN: 9BWDE21J7240xxxxx   Mileage: 145030km/90117miles
-------------------------------------------------------------------------------

Address 01: Engine Labels: 06A-906-032-AWP.lbl
Part No: 06A 906 032 HS
Component: 1.8L R4/5VT G 0008
Coding: 07500
Shop #: WSC 00000
VCID: 76EDE6CC520186AEB1B-5120
3VWSE69M62M193142 VWZ7Z0B4932131

1 Fault Found:
17579 - Angle Sensor 2 for Throttle Actuator (G188) Implausible Signal
P1171 - 35-10 - - Intermittent
Readiness: 0000 1001

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ASR.lbl
Part No: 1C0 907 379 K
Component: ASR FRONT MK60 0103
Coding: 0021505
Shop #: WSC 00000 785 00200
VCID: 32651ADCAEE9DA8E5D3-513C

1 Fault Found:
01314 - Engine Control Module
013 - Check DTC Memory - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 A
Component: 1M AIRBAG VW51 02 0004
Coding: 12621
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5102

1 Fault Found:
00591 - Seat Belt Switch; Driver (E24)
32-10 - Resistance Too High - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 806 J
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 07332
Shop #: WSC 00000
VCID: 2E5D0EACEAD1FE6E39B-5102
9BWDE21J7240xxxxx VWZ7Z0B5281213

1 Fault Found:
01177 - Engine Control Unit
64-10 - Not Currently Testable - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00000
VCID: F0E150D4B065289EEB7-5102

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 1J Komfortgerát HLO 0003
Coding: 00064
Shop #: WSC 00000
VCID: 37732BC8158B3FA66AD-4B18

Subsystem 1 - Part No: 1C1959801A
Component: 1J Tõrsteuer.FS KLO 0002

Subsystem 2 - Part No: 1C1959802A
Component: 1J Tõrsteuer.BF KLO 0002

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 E
Component: Radio ZSW 0010
Coding: 00031
Shop #: WSC 00000
VCID: 2245EA9CAE094A0EAD3-5120

No fault code found.

End ---------------------------------------------------------------------
 
Last edited:
   #2  

Jack@European_Parts

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Hey sorry was really having a hard time getting that ZPM installed to get back here.........:p

Okay

1 Fault Found:
17579 - Angle Sensor 2 for Throttle Actuator (G188) Implausible Signal
P1171 - 35-10 - - Intermittent
Readiness: 0000 1001


Lets define what this is in WD first G188 you have it right?

If you unplug the OXS sensors does this error go away?

 
   #3  

30secondgti

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Hi Jack,

Thanks for finding my thread. I don't have WD, how can I get it? I will unplug the OXS when my mechanic is back from holidays. I don't have a hoist and I'm not positive I can get myself under the car. It's slammed with body kit. I will take pictures of the engine bay and post them tonight or tomorrow. Sorry I havn't gotten those up yet.
 
   #4  

30secondgti

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I like star trek and star gate but you're kidding about the ZPM right? ;) lol
 
   #5  

Jack@European_Parts

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Who me I never kid.............:p

Have you changed the TV or cleaned it and lubricated it?

The picture above should suffice.

No worries on this low-rider.
You can do all these tests or overlays under the hood/cal area.

The tracks circled.......... are the ones you must go check.

Learning notes:

See current track Icon 186 in pic above? That is a star-gate in WD terms..... as I reference it.
It brings you to that destination current track when clicking on it in the actual WD........if supported!
When you get to the new world, it displays the origin current track at bottom of the page of the WD.......... not pictured here.

Star-gates also existed in Buck Rodgers if you recall.
The Orb ZPM also allowed for the travel to a far away land........... which the Princess and Commander Kane perused the new world with Buck aboard the destroyer.
 
   #7  

30secondgti

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Hi Jack@European_Parts,

Sorry about the delay.

Best update I can supply: Mechanic with the shop is gone on holidays until the end of august, Mobile Mechanic is gone until August 07, Tuner friend is gone until August 06.

It's just me and the car until then. I've been running the car since we flashed it back to stock. All the fault codes came back like I mentioned earlier, but I cleared all the DTC's a week ago and have been driving it. I know it's probably not the best to clear codes and keep driving. But I'm tired of not having use of this car. If anything all the same fault codes will come back in a week, maybe two. It's just a matter of time.

When our tuner is back this week we will order another used stock ecu from the auto wrecker (3rd one in 1 year!), install it and adapt it to the car. START FRESH, then I will check and clean the TB & TV and lubricate them.

We will then check, verify and conduct and output test on the wiring (G186, G188 and the rest of them), like you have suggested.

Will also pull the battery out and check all the ground. (4 I believe there are)

Wind shield wipers have been permanently off for the warmer months, ecu is easily accessible; I've gotten good at taking the cal off and replacing it ;) hopefully this is the last ecu and time I have to do this. Although we were considering keeping the flashed ecu, re flashing it with stage 2 and having it as a back up for days when the car is mechanically fixed, running up to par and when you wanna go fast....

Thanks again.
 
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   #8  

30secondgti

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Hi Jack@European_Parts,

I have 5 pictures of the engine bay. I'm uncertain how to post url images. I have always just browsed and found them.
 
   #10  

30secondgti

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Okay, so I've gotten 5 pictures of the engine bay outlinig a few areas. If further more detailed pictures are required, I am happy to get some more. Please let me know. Jack, please see my above post, dated (August 4th, 3:28 PM)















 
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   #11  

30secondgti

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Hey Jack,

Did you see my pictures, did they post properly?
 
   #12  

Jack@European_Parts

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Yes nice clean bay.

I un-approve of your type hose clamps.....yuke! RULE! Only use Zebra/Norma screw type or crimp type for 360 degree clamp force!

Okay that diverter you have is the spring maybe set to stiff? Please verify.

Sorry had to find another ZPM to get back here to establish a wormhole.
 
   #13  

30secondgti

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Where yah been?? usually its me that is MIA! ;)

Thanks, it came that way from previous owner. I've also used some meguiar's shine on various parts of the bay.

Type hose clamps or tight hose clamps?

The clamps came that way too, I haven't changed or added any. Aren't the ones currently installed stock? What's wrong with them, why would changing them be better? (i'm assuming these ones are too tight)?

Diverter Valve came that way with the car... Another thing on the list to check (DV spring) when my mechanic is back from holidays (end of August)

I also REALLY WANTED to Stress This: Our Tuner, My Landlord and myself all feel that the car is running rich. when the car idles on the driveway the exhaust is very strong. I can also smell it while the car is parked in the garage (not running). I suppose that could MEAN A NUMBER OF THINGS. Bad MAF or OXS are probably a cheap place to start? Interestingly enough, the car doesn't throw any faulty codes with a stock flash (like I've previously mentioned). Is this the case sometimes...running rich doesn't prompt any DTC's?

Encounter any Goa'uld or Borg along the way?
 
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   #14  

Jack@European_Parts

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TYPE!
Nope not stock.
These type clamps you have, cause leaks by ripping boots and don't seal 360 degree of clamp force.

Na saw a Wrathe hive ship, however, it was sleeping.......I am more concerned about Replicators recently crossing the Southern boarder of the USA here on Earth.

I would take a good look at the injectors being correct part # and that the fuel PSI/regulator is not set to high.
 
   #15  

30secondgti

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Well this is startling news I must say. I wonder why the previous owner put these no good clamps on...no wonder I could be running rich, perhaps a boost leak.

Haha no comment on the Replicators..up here in Canada; we're far away from all the hype and logistics.

I'm such a rookie. I have no idea where the fuel/ psi regulator is. I didn't even know that existed..

Sounds like my list of things to do just became one item longer.

Species 8472 has really been on my mind lately, run!
 
   #16  

jakematic

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These type clamps you have, cause leaks by ripping boots and don't seal 360 degree of clamp force.

Na saw a Wrathe hive ship, however, it was sleeping.......I am more concerned about Replicators recently crossing the Southern boarder of the USA here on Earth.
Said clamps caused the leak in the power conduit - Jack knows of where he speaks, damn close call on the Hippaforalkus...

I never let that junk on my ship. The Destiny is still on mission...
 
   #17  

30secondgti

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What about that double ground on the battery? That really seems like over kill...

Orion is really stepping up..?
 
   #18  

Jack@European_Parts

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Redundant rounds on hand or grounds are never a bad idea.
In this thing a requirement, since history shows this to be a solution throughout VW-AUDI time travel.

No matter what timeline I find myself in........... this problem never changes!

Hey...........on another note I found the planet which manufactures the ZPM/DHD parts for the ancient races.
 
   #19  

30secondgti

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I'll update after we do the aforementioned diagnostics and tests
 
   #20  

30secondgti

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So I just had a look under the hood since I had some free time today. Looks like some of the hose clamps are Eurojet...

Car is revving all by itself, fluctuating from 1000 rpms to about 180. Have lost almost all of the gas predal/ throttle control.

Ran yet another Auto-scan, and cleared all the DTC's, so the car is running semi normal (that is until I drive it around for a hour or two, all faults will come back)

We're installing a new stock ECU tomorrow evening.

Will update after its installed and adapted.

For some personal info and if anyone is interested, here's the Auto-scan below that I did when the car lost almost complete throttle response with ghost revving.

ABS fault code seems to be the new one (after things got worse and lost throttle response)

interesting....

Code:
Wednesday,20,August,2014,17:42:31:50875
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.2.0 (x64)
Data version: 20140212


VIN: 9BWDE21J7240xxxxx    
Mileage: 145080km-90148mi   


--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 1J (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
          76
 
VIN: 9BWDE21J7240xxxxx   Mileage: 145080km/90148miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06A-906-032-AWP.lbl
   Part No: 06A 906 032 HS
   Component: 1.8L R4/5VT     G   0008  
   Coding: 07500
   Shop #: WSC 00000  
   VCID: 76EDE6CC520186AEB1B-513C
   3VWSE69M62M193142     VWZ7Z0B4932131

2 Faults Found:
17972 - Throttle Actuator (J338) 
            P1564 - 35-10 - Under-Voltage during Basic Setting - Intermittent
17579 - Angle Sensor 2 for Throttle Actuator (G188) Implausible Signal 
            P1171 - 35-10 -  - Intermittent
Readiness: 0010 1001

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ASR.lbl
   Part No: 1C0 907 379 K
   Component: ASR FRONT MK60      0103  
   Coding: 0021505
   Shop #: WSC 00000 785 00200
   VCID: 32651ADCAEE9DA8E5D3-513C

1 Fault Found:
01314 - Engine Control Module 
            013 - Check DTC Memory - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 A
   Component: 1M AIRBAG VW51 02   0004  
   Coding: 12621
   Shop #: WSC 00000  
   VCID: 2245EA9CAE094A0EAD3-5120

1 Fault Found:
00591 - Seat Belt Switch; Driver (E24) 
            32-10 - Resistance Too High - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J0 920 806 J
   Component: KOMBI+WEGFAHRSP VDO V07  
   Coding: 07332
   Shop #: WSC 00000  
   VCID: 2E5D0EACEAD1FE6E39B-5120
   9BWDE21J7240xxxxx     VWZ7Z0B5281213

1 Fault Found:
01177 - Engine Control Unit 
            64-10 - Not Currently Testable - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00006
   Shop #: WSC 00000  
   VCID: F0E150D4B065289EEB7-5102

No fault code found.

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Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 C
   Component: 1J Komfortgerát HLO 0003  
   Coding: 00064
   Shop #: WSC 00000  
   VCID: 37732BC8158B3FA66AD-4B00

   Subsystem 1 - Part No: 1C1959801A
   Component: 1J Tõrsteuer.FS KLO 0002  

   Subsystem 2 - Part No: 1C1959802A
   Component: 1J Tõrsteuer.BF KLO 0002  

No fault code found.

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Address 56: Radio        Labels: 3B7-035-1xx-56.lbl
   Part No: 3B7 035 180 E
   Component:    Radio ZSW        0010  
   Coding: 00031
   Shop #: WSC 00000  
   VCID: 2245EA9CAE094A0EAD3-5120

No fault code found.

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