05 Golf BEW exhaust leak and other miscellaneous issues

   #1  

Hootiebird

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Hi all,
I posted on here quite some time ago then life happened and I'm finally back. When I start up my car it belches out a plume of smoke. This seems to just happen when being started for the first time in a while (cold). But it always fires right up and runs great. Unfortunately there is a slight exhaust leak that makes it's way into the cabin and I need to address it. I hear a hissing sound near the firewall but that's as far as I can pinpoint it. I grabbed around the air intake and couldn't hear a change or see anything. Crazy enough, after I did that, less exhaust was getting into the cabin. I was hoping running a scan could help pinpoint the problem.
Also I have random(to me) electrical stuff showing up with the scan. I can verify that I do indeed have issues with the power lock on the passenger side and with the hatch.
As always, I'm very appreciative of this community and any assistance is greatly appreciated!

Code:
Sunday,29,September,2019,14:47:32:51908
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 19.6.1.0 (x64)  HEX-V2 CB: 0.4508.4
Data version: 20190529 DS308.0
www.Ross-Tech.com


VIN: 9BWGR61J954021224   License Plate: 245PM 29SEP
Mileage: 306890km-190692mi   Repair Order: 



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


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: 9BWGR61J954021224   Mileage: 306890km-190692miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-016-BEW.lbl
   Part No SW: 038 997 016 R    HW: 028 101 181 2
   Component: R4 1,9L EDC G000SG  0282  
   Revision: 12345678    Serial number: VWZ7Z0D0763350
   Coding: 0150031
   Shop #: WSC 66565 257 00032
   VCID: 2D07F437310D922F51F-5184

1 Fault Found:
18996 - Turbocharger Boost Control Position Sensor Circuit 
            P2564 - 000 - Signal too Low
             Freeze Frame:
                    RPM: 0 /min
                    Torque: 0.0 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Lambda: -5.1 %
                    Absolute Pres.: 183.6 mbar
                    Absolute Pres.: 918.0 mbar

Readiness: 1 1 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ESP-F.lbl
   Part No: 1C0 907 379 M
   Component: ESP FRONT MK60      0102  
   Coding: 0019458
   Shop #: WSC 00000 785 00200
   VCID: 3431E153D227C3E71E1-5184

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 F
   Component: 08 AIRBAG VW61 0202 0003  
   Coding: 12344
   Shop #: WSC 00000  
   VCID: 270B061F16F1B87FAB3-5160

1 Fault Found:
00532 - Supply Voltage B+ 
            07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J0 920 907 E
   Component: KOMBI+WEGFAHRSP VDO V03  
   Coding: 15232
   Shop #: WSC 00000  
   VCID: 2B03FA2F0A199C1F4FB-5160
   9BWGR61J954021224     VWZ7Z0D0763350

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            80-10 - Single-Wire Operation - 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: 70B92D43E3BFBFC73A9-5160

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            80-10 - Single-Wire Operation - Intermittent

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 C
   Component: 8C Komfortgerát HLO 0004  
   Coding: 00258
   Shop #: WSC 00000  
   VCID: 372BD65FC65128FF3B3-4B1E

   Subsystem 1 - Part No: 1C1959801A
   Component: 8C Tõrsteuer.FS KLO 0202  

   Subsystem 2 - Part No: 1C1959802A
   Component: 8C Tõrsteuer.BF KLO 0202  

   Subsystem 3 - Part No: 1C0959811A
   Component: 8C Tõrsteuer.HL KLO 0202  

   Subsystem 4 - Part No: 1C0959812A
   Component: 8C Tõrsteuer.HR KLO 0202  

3 Faults Found:
01389 - Tailgate Open Switch (F124) 
            27-10 - Implausible Signal - Intermittent
01336 - Company Data Bus for Comfort System 
            80-00 - Single-Wire Operation
01359 - Internal Central Locking Switch; Passenger Side (E198) 
            27-10 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 3B7-035-1xx-56.lbl
   Part No: 3B7 035 180 G
   Component: RADIO 3CP          0007  
   Coding: 00031
   Shop #: WSC 00000  
   VCID: 2411111367C753678E1-5160

1 Fault Found:
00856 - Radio Antenna 
            36-10 - Open Circuit - Intermittent

End----------(Elapsed Time: 05:02, VBatt start/end: 13.1V/13.1V)-----------
 
   #2  

DrPeter

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Hello,


When I start up my car it belches out a plume of smoke. This seems to just happen when being started for the first time in a while (cold).
If this is a bluish color smoke??, this would typically be caused by oil leaking (over night?) into the combustion chambers, most likely from leaking valve stem seals or valve guide.

As for the fault code in the ECM, we have a Ross-Tech wiki page you can have a look at, P2564 - Turbocharger Boost Control Position Sensor Circuit: Signal too Low



Unfortunately there is a slight exhaust leak that makes it's way into the cabin and I need to address it. I hear a hissing sound near the firewall but that's as far as I can pinpoint it. I grabbed around the air intake and couldn't hear a change or see anything. Crazy enough, after I did that, less exhaust was getting into the cabin.

- Fix that exhaust leak! Carbon monoxide poisoning is real! and exhaust leaks can cause other concerns too, ECM fault codes, driveability concerns, etc.

- Try disconnecting the main connection at the vacuum pump and see if the noise goes away. If it does, have a close look at all the components on the vacuum circuit.



Also I have random(to me) electrical stuff showing up with the scan. I can verify that I do indeed have issues with the power lock on the passenger side and with the hatch.

This fault code would indicate a potential wiring/connection concern, since there are two separate wires for the CAN-Bus wiring, one of them has been compromised. Have a look at the controllers and their connections that have this fault code, looking for any concerns, water, corrosion, etc.

01336 - Company Data Bus for Comfort System
80-00 - Single-Wire Operation




Hope this helps,

drpeter
 
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   #3  

dieseldub

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Know what's great about diesels? Even without the exhaust gases passing through a catalytic converter, they produce such low amounts of hydrocarbons and carbon monoxide that you'll be just fine.

Not that it's pleasant to breathe the untreated exhaust fumes, but it won't give you carbon monoxide poisoning like a cracked exhaust manifold on a gas engine might (*cough*Ford Explorer*cough).

With that having been said, the BEW has a very, very common spot for an exhaust leak to occur. The lower EGR pipe likes to break on these. There was a couple EGR cooler recalls long ago and the last revision of the cooler also included installing an auxiliary support bracket to the driver side of the cooler to better keep it from moving around and stressing the pipes. Sometimes the pipe was simply installed in a way that it was stressed and it breaks, other times the pipe is stressed and breaks because one or more tabs have sheared and/or that auxiliary bracket is not bolted down any longer, thus allowing the cooler to move around.

As for the blue smoke on start up, just a quick puff seems to be pretty normal on PDs as they age. Sometimes is an injector or injector seal issue, sometimes it's a valve guide/seal issue. Not a huge deal so long as it runs fine otherwise. You can always try running a good fuel additive to ensure the injector nozzles are properly clean and getting better lubricity, sometimes that cuts down on the smoke.

As for the comfort system data bus error, being in single wire mode often means either a module is sending junk information onto the bus or the bus itself is shorted or a break in a wire somewhere in the system is creating an issue.

There is a measured value block in the convenience control module to see in realtime if the data bus is in single wire or 2 wire mode. What I'd recommend as a starting point is to unplug all 4 doors and check that measured value for data bus operation. If it goes back to 2 wire mode with every door unplugged, then plug back in one door at a time until you see the single wire reading return in the measured values. The door that trips it back into single wire mode is where you can start your search for either broken data bus wires between that door's connector station and the window motor (which also acts as that door's control module). If the wires check out OK, it's possible that you simple have a bad module that's part of the window motor.

You can use your auto scan results to tell what part number and color code window motor to order. You can't just replace a window motor with any other mk4 window motor. There was a change in data bus speed and number of messages sent midway through 2002. Mixing window motors causes data bus crashes too.

Also, the radio is on the same data bus as the convenience/comfort system. If unplugging all the doors doesn't restore 2 wire operation, try unplugging the radio. Cars with steering wheel controls also have a connection to the comfort data bus via the steering wheel control module, but I did not see that module in your autoscan so I'm going to assume your Golf is not equipped with steering wheel controls.
 
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   #4  

dieseldub

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For reference, this is a copy and paste from your auto scan, I'm adding notes to it to tell you which part numbers correspond with which door:

Driver's window motor
Subsystem 1 - Part No: 1C1959801A
Component: 8C Tõrsteuer.FS KLO 0202

Passenger front window motor:
Subsystem 2 - Part No: 1C1959802A
Component: 8C Tõrsteuer.BF KLO 0202

Driver rear window motor:
Subsystem 3 - Part No: 1C0959811A
Component: 8C Tõrsteuer.HL KLO 0202

Passenger rear window motor:
Subsystem 4 - Part No: 1C0959812A
Component: 8C Tõrsteuer.HR KLO 0202

Usually the "8C" you see in the Component information is a partial color code, you may have to consult with the dealer to get the correct color code specific to your car. Though I have used different color codes in the past without issue, so long as the rest of the part number matched.

From what partslink and an old copy of ETKA suggest, 2005 Brazilian built Golfs should use 017 as the part number color code, so if you were ordering, for example, a new driver side rear window motor, you'd use part number 1C0 959 811 A 017. You just tack the "color code" (017 in your case) to the end of the main part number.
 
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