VW CARAVELLE 2,5 petrol AVT

[Orchid70]

Hi
I have a problem and not sure what to look at - if its the EVAP valve thats needed changing.

VIN: WV2ZZZ70Z1H108351

Friday,06,November,2020,10:28:33:18201
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 19.6.2.0 (x64)  HEX-V2 CB: 0.4508.4
Data version: 20190930 DS308.0
www.Ross-Tech.com

Dealer/Shop Name: Firma Johannes Bruun 
Workshop Code: 000 02013 000000

VIN:    License Plate: SFT984
Mileage: 213360km-132575mi   Repair Order: 



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Chassis Type: 7D - VW Transporter/Multivan (1996 > 2004)
Scan: 01 02 03 08 15 17 18 19 22 25 35 37 56

   Mileage: 213360km-132575miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: Redir Fail!
   Part No: 023 906 033 B
   Component: 2.5l/2V SIMOS3  00HS3603  
   Coding: 00001
   Shop #: WSC 00000  
   VCID: 0C41A66AEF5F26F7A5F-51CE

3 Faults Found:
16514 - Oxygen (Lambda) Sensor B1 S1 
            P0130 - 35-00 - Malfunction in Circuit
16688 - Cylinder 4 
            P0304 - 35-10 - Misfire Detected - Intermittent
17834 - EVAP Purge Valve (N80) 
            P1426 - 35-10 - Open Circuit - Intermittent
Readiness: 0010 0001

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Address 15: Airbags        Labels: 1J0-909-60x-VW3.lbl
   Part No: 1J0 909 603 BL
   Component: AIRBAG VW3 -        V04  
   Coding: 16972
   Shop #: WSC 02743  
   VCID: 74B1DE8A97AF5E37DDF-4B9A

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 7D0-920-xxx-17.lbl
   Part No: 7D0 920 803 
   Component: T4-KOMBIINSTR. VDO V22   
   Coding: 01151
   Shop #: WSC 00000  
   VCID: 619FA7DE385DDB9FA69-5160

No fault code found.

End----(Elapsed Time: 03:08, VBatt start/end: 12.1V/12.0V. VIgn 0.0V)------

I have read the codes with Odis Service as well - and it says the lambda code is intermittent and the other two are static.

 

[Bruce]

The malfunction in the O2 sensor is where I would start. Don't assume it is a bad sensor. Often the intermittent problems are wiring related.

Once that is cleared, then look to the evap to see what is up with that. Open circuit could mean a bad part or again, bad wiring.

Go to erwin and get the wiring diagrams.

 

[Orchid70]

Thank you!!
Car owner bought the car and soon after the engine light came on - instead of leaving it back - he came by and I checked the fault codes present - the only one present then, was the lambda sensor.
So I ordered one and changed it at the same time we did service and went off to MOT.
MOT failed with too low lambda and too high both CO's.
When hubby came back - I had all these three fault codes.
=/

 

[Orchid70]

Finally got this van indors.
And couple hours after driving it in - opened the hood and could clearly smell burned electronics.
Four components share the same 12V:
Both lambdas (G39) (G130)
Air mass meter (G70)
Charcoal filter solenoid (N80)

Fault codes come back in different order:
On First lambda (G39) (changed to new) sometimes intermittent sometimes permanent
On (N80) (tested OK) someetimes intermittent sometimes permanent
On 4 cylinder missfire intermittent

I have no voltage and 1,9 ohm resistance to earth, on all the componet CONNECTORS (with lambdas disconnected)
MAF
Charcoal canister sensor
Lambda 1
Lambda 2

BUT - When I take out the fuse S117 in the cabin (the right hand side of the two 15A fuses, on the top of the relay plate) - no resistance in the connectors!
So - the short is in the cabin somewhere. I hate these cars,

 

[Orchid70]

I have a tone generator (after a tip here, thanks) but I cannot follow the tone from the fuse and further - there is no tone! Earlier when I have located damaged wires in a engine loom (Caddy) it was easy to follow the tone up till the damage. But here - I have no tone on the wire from fuse S117 to - yes where does it go?
Would it be easier to make a new 2,5 wire, directly from the battery plus to the fuse S117?

 

[Orchid70]

I took the fuel pump relay (167) to test.

Yesterday, for some reason, it did not let voltage through. Today after leaving it indoors, I tested it again and OK. I tested it back and furth yesterday, then desided today to use an other battery toafay - it works with both batteries. So dont know why it behaved that way yesterday.
Tested also Voltage at lambda one. 85 mV ignition on.
And finelly I realised to start engine to measure voltage:
14,2V with engine running.
So no problems with voltage to heater element on Lambda.
Been chasing the wrong wire.
Back to zero.

 

[Orchid70]

I measerued resistance on wires between G80 and Lambda and ECU.
All wires to ECU had 0-0,2 ohm resistance. So OK.

Can it be the ECU.
Any ideas to how to check the ECU before changing it?

 

[Orchid70]

Now I have had all the pins out in the connectors to prelambda and evap solenoid - as well as the corresponding pins on ECU side are checked - they all are OK.
Would the intermittent fault on missfire on cylinder 4 also indicate towards ECU? Its a Simons 3.5.
Perhaps I should take out the oscilloskope and see how that injector behaves?

 

[Orchid70]

I think Im getting closer now.
What do you think of these spikes at over 50V to EVAP solenoid??

 

[Bruce]

As an EE, those spikes would be the normal inductive kick from the solenoid coil. Current is flowing when the signal is near 0 and then on turn off, the voltage will fly to a higher voltage as the stored energy in the coil dissipates. Normal operation...

The electronics likely have a limiting circuit that allows the solenoid to fly back to a prescribed voltage at which it is clamped. This allows the solenoid to disengage quickly by letting the magnetic field collapse.

 

[Orchid70]

Bummer.
I didnt see those high voltages in the waveforms found on the internet. So thought I had found something. But - the fault code was intermittent... so I should have seen a fault code here - and there was no.
Thank you!
I dont know where to look, from here =(
When I activated the EVAP solenoid with computer (30 seconds) I could here a hissing noise, from the inlett manifold side - this car doesnt have EGR or Secondary Air Injection Solenoid (N112). I dont know what could make that hissing noise?
What could that be?

 

[Orchid70]

I think I have found the cause for the P0130.

Measured voltage to heater element on pre cat lambda - engine running:
Ground from ECU

Following is with ground taken from battery:

It looked like the fault code was set when the voltage got under 10.5V.
The warmer the enigne got - the higher the voltage got - or the ground was better.