2005 Touareg V8 - many warning lights, no start, lots of No Signals

[the brit]

The car was sitting while I had to the timing chain tensioner; the battery definitely went flat during that time. No apparent water inside the passenger compartment, but it has previously had an issue with the sunroof and water ingress. Here's the autoscan, thanks!

Thursday,20,September,2018,20:58:04:19576
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 18.2.1.2 (x64)  HEX-NET CB: 0.4411.4
Data version: 20180518 DS287.1
www.Ross-Tech.com


VIN: WVGMM77L55D064447   License Plate:


Chassis Type: 7L (7L - VW Touareg (2003 > 11/2006))
Scan: 01 02 03 05 06 08 09 11 13 15 16 17 18 19 1C 22 29 32 34 36
          37 39 3C 46 47 55 56 57 64 65 68 69 6C 6D 6E 75 76 77

VIN: WVGMM77L55D064447   Mileage: 194050km-120577miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 077-907-560-AXQ.lbl
   Part No SW: 4D0 907 560 DB    HW: 8E0 907 560
   Component: 4.2L V8/5V      G   0020
   Revision: 00000000    Serial number: VWZ3Z0E7311304
   Coding: 0007875
   Shop #: WSC 31414 000 00000
   VCID: E99AF732C1351A0C10-5160

4 Faults Found:
18053 - Powertrain Data Bus
            P1645 - 008 - Missing Message from AWD Controller
18034 - Powertrain Data Bus
            P1626 - 008 - Missing Message from TCU - MIL ON
18057 - Powertrain Data Bus
            P1649 - 008 - Missing Message from ABS Controller
18005 - Powertrain Databus
            P1597 - 008 - Missing Message from Level Control System (J197)
Readiness: 0010 1101

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth.        Labels: 3D0-909-13x-05.lbl
   Part No SW: 3D0 909 135 R    HW: 5WK 470 26
   Component: 17 Kessy            6610
   Revision: 66105312    Serial number: VWZ3Z0E7311304
   Coding: 0131304
   Shop #: WSC 31414 000 00000
   VCID: B4245646D67797E473-5160

   Subsystem 1 - Part No: XXXXXXXXXXX
   Component: ELV                 XXXX

6 Faults Found:
01315 - Transmission Control Module
            004 - No Signal/Communication
01316 - ABS Control Module
            004 - No Signal/Communication
00576 - Terminal 15
            009 - Open or Short to Ground
00185 - Control Circuit; Relay for Supply Voltage Terminal 15
            009 - Open or Short to Ground
01299 - Diagnostic Interface for Data Bus (J533)
            013 - Check DTC Memory
00183 - Interior Access/Start Authorization Antenna 1 (R138)
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 06: Seat Mem. Pass        Labels: None
   Part No: 7L0 959 760
   Component: Sitzverstellung     0701
   Shop #: WSC 00000 000 00000
   VCID: F7BEA14A8781BCFC96-5160

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 7L6-907-040.clb
   Part No: 7L6 907 040 H
   Component: CLIMAtronic R/L   X 3716
   Coding: 0020030
   Shop #: WSC 31414 000 00000
   VCID: B5226B42DD0D8EEC44-5160

2 Faults Found:
01592 - Air Quality Sensor (G238)
            010 - Open or Short to Plus
01299 - Diagnostic Interface for Data Bus (J533)
            008 - Implausible Signal

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels:. 7Lx-937-049-V1.clb
   Part No: 7L6 937 049 M
   Component:                     3001
   Coding: 0105692
   Shop #: WSC 31414 000 00000
   VCID: C6C01C8EB0EB1574DD-5160

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 3D0-909-601.lbl
   Part No: 3D0 909 601 H
   Component: 01 Airbag 8.4E++H01 0562
   Revision: BB38727     Serial number: 0000157?
   Coding: 0012337
   Shop #: WSC 31414 000 00000
   VCID: A81CB2361ABFE304CF-5160

   Subsystem 1 - Part No: 7L0 959 339 D
   Component: BF-Gewichtsens. 005 0007

1 Fault Found:
01316 - ABS Control Module
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 255
                    Time Indication: 0


-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 7L6-953-549.lbl
   Part No: 7L6 953 549 D
   Component: Lenksäulenmodul     3301
   Coding: 0000032
   Shop #: WSC 31414 000 00000
   VCID: C0CC0A9692CF3B44E7-5160

1 Fault Found:
00532 - Supply Voltage B+
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 7L6-920-xxx-7LA.lbl
   Part No: 7L6 920 981
   Component: KOMBIINSTRUMENT RB8 3110
   Coding: 0007231
   Shop #: WSC 31414 000 00000
   VCID: F6A0AC4E808BC5F48D-5160

4 Faults Found:
01310 - Level Control System Control Module (J197)
            004 - No Signal/Communication
01315 - Transmission Control Module
            004 - No Signal/Communication
01316 - ABS Control Module
            004 - No Signal/Communication
02053 - Control Module for Transfer Case (J646)
            004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901
   Component: Gateway K<>CAN      0101
   Coding: 0000006
   Shop #: WSC 31414 000 00000
   VCID: F0AC9A56E2EFEBC457-5160

5 Faults Found:
00778 - Steering Angle Sensor (G85)
            004 - No Signal/Communication
01310 - Level Control System Control Module (J197)
            004 - No Signal/Communication
01315 - Transmission Control Module
            004 - No Signal/Communication
01316 - ABS Control Module
            004 - No Signal/Communication
02053 - Control Module for Transfer Case (J646)
            004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 1C: Position Sensing        Labels: 7L6-919-879.lbl
   Part No: 7L6 919 879 A
   Component: JCI PathPoint       2200
   Shop #: WSC 00000 000 00000
   VCID: C5C21B828DED1E6CD4-5160

No fault code found.

-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr        Labels: None
   Part No: 7L0 959 760
   Component: Sitzverstellung     0701
   Shop #: WSC 00000 000 00000
   VCID: F7BEA14A8781BCFC96-5160

2 Faults Found:
00668 - Supply Voltage Terminal 30
            002 - Lower Limit Exceeded - Intermittent
01317 - Control Module in Instrument Cluster (J285)
            013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 37: Navigation        Labels: 7L6-919-887-DVD.lbl
   Part No: 7L6 919 887 C
   Component:      Navigation     0814
   Coding: 0000101
   Shop #: WSC 31414 000 00000
   VCID: C6C01C8EB0EB1574DD-5160

1 Fault Found:
00668 - Supply Voltage Terminal 30
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 7L0-959-933.lbl
   Part No: 7L0 959 933 E
   Component: 2L HSG              0201
   Coding: 0000085
   Shop #: WSC 31414 000 00000
   VCID: BE30746EE83B4DB495-4B1E

   Subsystem 1 - Part No: 7L0 959 701 H
   Component: Tuersteuergeraet FS 0201

   Subsystem 2 - Part No: 7L0 959 702 H
   Component: Tuersteuergeraet BF 0201

   Subsystem 3 - Part No: 7L0 959 703 D
   Component: Tuersteuergeraet HL 0201

   Subsystem 4 - Part No: 7L0 959 704 D
   Component: Tuersteuergeraet HR 0201

3 Faults Found:
00576 - Terminal 15
            008 - Implausible Signal
01312 - Powertrain Data Bus
            013 - Check DTC Memory
00486 - Front Passengers Outside Door Handle Central Locking Button (E370)
            007 - Short to Ground

-------------------------------------------------------------------------------
Address 47: Sound System        Labels:
   VCID: D5E2CBC22C4DAEECA4-5160
   Note: Excessive Comm Errors


-------------------------------------------------------------------------------
Address 56: Radio        Labels: 7L6-035-186-CD.lbl
   Part No: 7L6 035 186 A
   Component:        Radio        0814
   Coding: 0004062
   Shop #: WSC 31414 000 00000
   VCID: B12A5F522965A2CC18-5160

1 Fault Found:
00668 - Supply Voltage Terminal 30
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 68: Wiper Electr.        Labels: 7L0-955-119-V2.clb
   Part No: 7L0 955 119 K
   Component: Front Wiper         4027
   Coding: 0000855
   Shop #: WSC 31414 000 376832
   VCID: BC347E66FE275FA4BB-5160

   Subsystem 2 - Part No: 1K0 955 559 M  Labels: 1K0-955-559-AF.CLB
   Component: RegenLichtSens 005  0605
   Coding: 00217125
   Shop #: WSC 31414

1 Fault Found:
01299 - Diagnostic Interface for Data Bus (J533)
            013 - Check DTC Memory

-------------------------------------------------------------------------------
Address 69: Trailer        Labels: 7L0-907-383-1D2.lbl
   Part No SW: 7L0 907 383 N    HW: 7L0 907 383 N
   Component: J345  Anhaenger     0080
   Revision: 4A012001    Serial number: 00000366920397
   Coding: 0016386
   Shop #: WSC 00512 001 24584
   VCID: BFCE096AEF3144BC9E-5160

2 Faults Found:
00532 - Supply Voltage B+
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 3
                    Fault Frequency: 3
                    Reset counter: 40
                    Time Indication: 0

00576 - Terminal 15
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 0
                    Time Indication: 0


-------------------------------------------------------------------------------
Address 6E: Ctrl Head Roof        Labels: None
   Part No: 7L6 919 044 K
   Component: DACHDISPLAY         0538
   Revision: 00700538    Serial number: 2009289.06
   Shop #: WSC 31414 000 00000
   VCID: BFCE096AEF3144BC9E-5160

No fault code found.

End----(Elapsed Time: 09:17, VBatt start/end: 12.3V/12.3V. VIgn 0.0V)------

 

[Uwe]

Assuming you having already done this: Clear all fault codes. Cycle the ignition. Re-scan so we can see what comes back and is actually current.

TCU, ABS, and AWD modules definitely seem to be off-line. Check a wiring diagram to see if perhaps these have a common point of voltage supply, either switched ("Terminal 15") or unswitched ("Terminal 30").

This fault in the 05-Acc/Start Auth ("Kessy") module bothers me the most:

00576 - Terminal 15
            009 - Open or Short to Ground

I suspect if you find the cause for that, many of the other problems will be dealt with.

-Uwe-

 

[Dana]

Hi Jamie,

I agree with Uwe. I'd focus on that specific circuit .

If memory serves the KESSY controls that Term 15 relay directly and you'll prob find a corroded wire to/from the relay and KESSY module.

 

[the brit]

Thanks

That was the scan after many, many clearances of codes. I had to go into individual modules to do some clearing even.

I've now got the drivers side carpet up; there was water residue but no standing water, and the wiring appears to be in perfect shape - not what I expected to find.

I'll concentrate on KESSY based on both of your guidance, thank you. I'm trawling through ELSA looking for hints.

 

[Lgibson]

Club Touareg has a DIY on replacing failed MOSFET’s in the Kessy, a known issue in ‘05’s.

 

[the brit]

Club Touareg has a DIY on replacing failed MOSFET’s in the Kessy, a known issue in ‘05’s.

Thanks. I have found a thread there discussing it which I'll read shortly.

 

[Uwe]

Club Touareg has a DIY on replacing failed MOSFET’s in the Kessy, a known issue in ‘05’s.

Thanks. I have found a thread there discussing it which I'll read shortly.

Link please?

(We have no problem with links to useful info on other forums here)

-Uwe-

 

[the brit]

I have jumped Pins 30 to 87 on the J329 Terminal 15 relay under the drivers seat, and the car will now shift out of park and allow it to be driven. Transmission remains locked in 3rd gear, and BRAKE FAULT STOP warning light is displayed, along with all other major warning lights. But it shows signs of life. The diagnosis continues.

 

[the brit]

Link please?

(We have no problem with links to useful info in other forums here)

-Uwe-

This is where the thread seems to start getting interesting:
https://www.clubtouareg.com/forums/f43/anyone-had-a-kessy-module-rebuilt-45716-6.html

EDIT: I don't see people reporting that the KESSY MOSFET / resisters cause the shutdown of the vehicle; just the loss of keyless entry etc.

 

[the brit]

Terminal 15 Relay

K - Ro/Ws 0.5 to T81/14 - will check
85 - Br/Ro 0.5 - to KESSY T81/58 - will check
86 - Ro/Ws 0.5 - to Fuse 39 - should be working as instrument cluster and heated seats work - but they also work when relay isn't installed sooo....
87 - SW 6.0 - works when jumped
30 - Ro 6.0 - works when jumped

 

[the brit]

Found it..!

Two AWFUL broken wires inside the lower a-pillar area. HORRIBLE DESIGN.

The 85, 87, and either the K or 86, wires have a factory joint in this area, which were simply crimped and taped from the factory. No real connection, and no water proofing or anything else. These are the only wires in this area that have such a joint. Fuck the engineers who did this one.

I connected them with a standard VW repair connection (crimp and heat butt connector), and now all major warning lights on the dashboard have gone. I still haven't scanned (I'm still doing a happy dance, literally), but do have CEL and a brake pad warning light (which I think is probably correct).

Will update with a scan shortly. Thanks everyone!