3.0 TDI faults.

   #1  

Rayston

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Hi All,

I've had the dreaded "Exhaust Workshop" problem intermittently for a while and the VCDS scan has shown 2 faults - throttle valve

controller and intake manifold runner. Now however I suddenly have a flashing glow plug light and the car going into limp mode.

The scan shows DPF restricted/clogged and a search on Ross-Techs Wiki suggests performing a service regeneration. Attempting this

in line with their instructions for the BMK engine leads to no action and, in view of the figures shown in the various scans, I

wonder if the fault report is spurious.

I've had the car since new in 09/2006, serviced on schedule by VW and have avoided short runs as far as possible. The batteries

are original but OK so I'm told. **** see below****

I'd be most grateful if someone can point me in the right direction to sort these problems. Ash & soot levels seem low and I wonder

if that is why the regen' doesn't start.

Here are the various original scans:-

Code:
8 FAULTS REPORTED BY AUTO-SCAN 

Monday,02,November,2015,15:08:04:16346
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 15.7.1.0 (x64)
Data version: 20150904
www.Ross-Tech.com

Repair Order: 02/11/15
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
Chassis Type: 3D (3D - VW Phaeton (2002 > 2006))
Scan: 01 02 03 05 06 07 08 09 11 13 15 16 17 18 19 23 27 28 29 2E
          34 36 37 38 39 46 47 55 56 57 65 66 68 69 71 75 76 77
 
VIN: WVWZZZ3D                     Mileage: 112250km-69748miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 059-907-401-ASB.clb
   Part No SW: 3D0 907 401 A    HW: 8E0 907 401 AB
   Component: 3.0L V6TDI  G000AG  0010  
   Revision: --H01---    Serial number: VWZ3Z0F1504912
   Coding: 0011773
   Shop #: WSC 01065 000 00000
   VCID: 1D3195DBC78E14D656-5140

3 Faults Found:
004120 - Intake Manifold Runner (Bank 2) 
               P1018 - 001 - Lower limit not reached
             Freeze Frame:
                    Fault Status: 01100001
                    Fault Priority: 0
                    Fault Frequency: 4
                    Reset counter: 255
                    Mileage: 112258 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 714 /min
                    Torque: 42.9 Nm
                    Speed: 0.0 km/h
                    Voltage: 14.44 V
                    Duty Cycle: 80.9 %
                    Duty Cycle: 89.2 %
                    Duty Cycle: 80.9 %

005445 - Throttle Valve Controller 
               P1545 - 002 - Malfunction
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 0
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 112258 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 714 /min
                    Torque: 46.8 Nm
                    Speed: 0.0 km/h
                    Voltage: 14.59 V
                    Duty Cycle: 92.7 %
                    Bin. Bits:    010  
                    Mass Air / Rev.: 452.4 mg/str

009263 - Diesel Particulate Filter (Bank 1) 
               P242F - 001 - Restricted/Clogged - MIL ON
             Freeze Frame:
                    Fault Status: 11100001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 112258 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 714 /min
                    Torque: 42.9 Nm
                    Speed: 0.0 km/h

Readiness: 1 3 0 0 0 
-------------------------------------------------------------------------------

Address 05: Acc/Start Auth.        Labels: 3D0-909-13x-05.lbl
   Part No SW: 3D0 909 139     HW: 5WK 484 94
   Component: 0C Kessy            6700  
   Revision: 67006015    Serial number: VWZ3Z0F1504912
   Coding: 0004328
   Shop #: WSC 01065 000 00000
   VCID: 66C3FA375258170EC7-5140

   Subsystem 1 - Part No: XXXXXXXXXXX 
   Component: ELV                 XXXX

1 Fault Found:
00165 - Switch for Transmission Position P/N 
            007 - Short to Ground - Intermittent
-------------------------------------------------------------------------------

Address 16: Steering wheel        Labels: 3D0-953-549.lbl
   Part No: 3D0 953 549 D
   Component: Lenksäulenmodul     3401  
   Coding: 0000031
   Shop #: WSC 01065 000 00000
   VCID: 2E534217BA289F4EFF-5140

1 Fault Found:
01336 - Company Data Bus for Comfort System 
            004 - No Signal/Communication - Intermittent
-------------------------------------------------------------------------------

Address 47: Sound System        Labels: 7Lx-035-4xx-47.lbl
   Part No: 3D0 035 465 A
   Component: 08K-AUDIOVERST      0112  
   Shop #: WSC 00000 000 00000
   VCID: 1F4DAFD3CD8206C644-5140

2 Faults Found:
00418 - Front Right DSP Mid-Bass Speaker (R102) 
            011 - Open Circuit
00874 - Treble Speaker Front Left (R20) 
            011 - Open Circuit
-------------------------------------------------------------------------------

Address 71: Battery Charger        Labels: 3D0-915-181.lbl
   Part No: 3D0 915 181 D
   Component: Batteriemanagement  2800  
   Shop #: WSC 00000 000 00000
   VCID: 2447A03FE4E4251E19-5140

1 Fault Found:
00086 - Parallel Battery Connection Relay (J581) 
            011 - Open Circuit - Intermittent
-------------------------------------------------------------------------------
SRI REPORT

VCDS Release 15.7.0:  SRI Reset
Control Module Part Number: 3D0 920 982 H       Labels:  3D0-920-xxx-17.lbl
Component:KOMBIINSTRUMENT RB8 0610, Coding:0023411
Operation: Please select an operation
************************************************************************************************************************
Channel  	Description                                       	Unit      	Current val.  	New val.  
02       	Service Reminder Status                           	          	0             	---       
40       	Mileage since Service                             	km x100   	103           	---       
41       	Time since Service                                	Days      	454           	---       
42       	Min Mileage to Service                            	km x100   	15            	---       
43       	Max Mileage to Service                            	km x100   	30            	---       
44       	Max Time to Service                               	Days      	730           	---       
45       	Oil Quality                                       	          	4             	---       
47       	Soot Quantity                                     	km x100   	58            	---       
48       	Thermal Load                                      	km x100   	60            	---       
49       	Min Time to Service                               	---       	---           	---       
************************************************************************************************************************
--------------------------------------------------------------------------------
MEASUREMENT BLOCKS

                Address 01: Engine  (3D0 907 401 A)

16:23:19 Group 007: Temperatures
  17.1°C  Fuel Temperature (G81)
  66.6°C  Oil Temperature 
  24.3°C  Intake Air Temperature (G72)
  67.5°C  Coolant Temperature (G62)

16:23:19 Group 104: Diesel Particle Filter (DPF)
  0.20  Particle Filter Oil Ash Volume
  56.7  Particle Filter Carbon Mass (calc.)
  10.2  Particle Filter Carbon Mass (act.)
  2090 km  Mileage 

16:23:19 Group 102: Diesel Particle Filter (DPF)
  133.4°C  Temperature prior Precatalytic Converter
  135.7°C  Temperature 
  15.7 mbar  Particle Filter Different. Pressure
  11.8 mbar  Particle Filter Offset Different. Pressure

16:29:52 Group 100
  777 /min  RPM 
  123.9°C  Temperature 
  0.0  (no units) 
        1   Bin. Bits 

16:29:52 Group 101
  11111001  Bin. Bits 
  11111111  Bin. Bits 
  00000000  Bin. Bits 
       000  Bin. Bits 

16:29:52 Group 102: Diesel Particle Filter (DPF)
  127.6°C  Temperature prior Precatalytic Converter
  123.9°C  Temperature 
  15.7 mbar  Particle Filter Different. Pressure
  11.8 mbar  Particle Filter Offset Different. Pressure

****** 10 days later ********

I've now renewed the left AGM battery and fully charged the starter battery and, lo & behold,all but 4 of the faults have vanished.

Sadly, the dreaded "Exhaust Workshop" problem and flashing glow plug light with the car going into limp mode are still there.

The scan shows DPF restricted/clogged but attempting a service regeneration again leads to no activity which makes me suspect

there's now't wrong with the DPF.

I'm planning on refurbishing the swirl flaps but would like to bottom out the diagnosis on all three engine faults first. I wonder

if anyone who recognises the problems could look over the story and give me a view?

Here are the latest various scans though I wonder if I'm reading the right measuring blocks:-

Code:
Thursday,12,November,2015,15:43:14:16346
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 15.7.1.0 (x64)
Data version: 20150904
www.Ross-Tech.com

VIN: WVWZZZ3DZ   License Plate:
Mileage: 112290km-69773mi   Repair Order: 12/11/15 after run
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
Chassis Type: 3D (3D - VW Phaeton (2002 > 2006))
Scan: 01 02 03 05 06 07 08 09 11 13 15 16 17 18 19 23 27 28 29 2E
          34 36 37 38 39 46 47 55 56 57 65 66 68 69 71 75 76 77
 
VIN: WVWZZZ3DZ   Mileage: 112290km-69773miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 059-907-401-ASB.clb
   Part No SW: 3D0 907 401 A    HW: 8E0 907 401 AB
   Component: 3.0L V6TDI  G000AG  0010  
   Revision: --H01---    Serial number: VWZ3Z0F1504912
   Coding: 0011773
   Shop #: WSC 01065 000 00000
   VCID: 1D3195DBC78E14D656-5140

3 Faults Found:
004120 - Intake Manifold Runner (Bank 2) 
               P1018 - 001 - Lower limit not reached
             Freeze Frame:
                    Fault Status: 01100001
                    Fault Priority: 0
                    Fault Frequency: 7
                    Reset counter: 255
                    Mileage: 112277 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Torque: 167.7 Nm
                    Speed: 0.0 km/h
                    Voltage: 12.54 V
                    Duty Cycle: 20.5 %
                    Duty Cycle: 88.8 %
                    Duty Cycle: 20.5 %

005445 - Throttle Valve Controller 
               P1545 - 002 - Malfunction
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 0
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 112277 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Torque: 167.7 Nm
                    Speed: 0.0 km/h
                    Voltage: 12.54 V
                    Duty Cycle: 92.7 %
                    Bin. Bits:    010  
                    Mass Air / Rev.: 0.0 mg/str

009263 - Diesel Particulate Filter (Bank 1) 
               P242F - 001 - Restricted/Clogged - MIL ON
             Freeze Frame:
                    Fault Status: 11100001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 112277 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Torque: 167.7 Nm
                    Speed: 0.0 km/h

Readiness: 1 3 0 0 0 
-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 09L-927-760.lbl
   Part No SW: 09L 927 760 J    HW: GS1 9.1 1.4 
   Component: AG6 09L 3.0lTDI RdW 2205  
   Revision: 00000001    Serial number:        4218860
   Coding: 0000001
   Shop #: WSC 00000 000 00000
   VCID: 3E7372576A486FCE6F-5140

No fault code found.
-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 3D0-614-517.lbl
   Part No: 3D0 614 517 AK
   Component: ESP 5.7 allrad  H33 0047  
   Coding: 0008356
   Shop #: WSC 01065 000 00000
   VCID: 6BD58B0349BA2A6698-5124

No fault code found.
-------------------------------------------------------------------------------
Address 05: Acc/Start Auth.        Labels: 3D0-909-13x-05.lbl
   Part No SW: 3D0 909 139     HW: 5WK 484 94
   Component: 0C Kessy            6700  
   Revision: 67006015    Serial number: VWZ3Z0F1504912
   Coding: 0004328
   Shop #: WSC 01065 000 00000
   VCID: 66C3FA375258170EC7-5140

   Subsystem 1 - Part No: XXXXXXXXXXX 
   Component: ELV                 XXXX

No fault code found.
-------------------------------------------------------------------------------
Address 07: Control Head        Labels: 3D0-035-00x-07.lbl
   Part No: 3D0 035 007 AR
   Component:    ZAB COCKPIT      0253  
   Coding: 0400405
   Shop #: WSC 01065 000 00000
   VCID: 69D9F10B43463876EA-5140

No fault code found.
-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3D0-907-040.lbl
   Part No: 3D0 907 040 J
   Component: Climatronic D1      2031  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 2541BD3BEFDEDC160E-5140

No fault code found.
-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3D0-937-049-V2.clb
   Part No SW: 3D0 937 049 L    HW: 3D0 937 049 L
   Component: J519                6200  
   Revision: -4003---    Serial number: --------------
   Coding: 600100002A211D000000000000000000
   Shop #: WSC 00490 210 84717
   VCID: 33655363510AB2A690-515E

No fault code found.
-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 3D0-909-601.lbl
   Part No: 3D0 909 601 E
   Component: 0H Airbag 8.4E+ H10 0935  
   Coding: 0012360
   Shop #: WSC 01065 000 00000
   VCID: 2541BD3BEFDEDC160E-5140

No fault code found.
-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 3D0-953-549.lbl
   Part No: 3D0 953 549 D
   Component: Lenksäulenmodul     3401  
   Coding: 0000031
   Shop #: WSC 01065 000 00000
   VCID: 2E534217BA289F4EFF-5140

No fault code found.
-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 3D0-920-xxx-17.lbl
   Part No: 3D0 920 982 H
   Component: KOMBIINSTRUMENT RB8 0610  
   Coding: 0023411
   Shop #: WSC 01065 000 00000
   VCID: 2D51451BB72EE456C6-5140

No fault code found.
-------------------------------------------------------------------------------
Address 18: Aux. Heat        Labels: None
   Part No: 3D0 815 005 AG
   Component: Standheizung        2426  
   Shop #: WSC 01065 000 00000
   VCID: 62CBE627BE706B2E2B-515E

No fault code found.
-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<>CAN      0101  
   Coding: 0000006
   Shop #: WSC 01065 000 00000
   VCID: 70EF9C6F609CC9BEAD-5140

No fault code found.
-------------------------------------------------------------------------------
Address 29: Left Light        Labels: 3D0-909-157.lbl
   Part No: 3D0 909 157 A
   Component: EVG GDL+AutoLWR(l)  0001  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 275DB73395D2CE063C-5140

No fault code found.
-------------------------------------------------------------------------------
Address 34: Level Control        Labels: 3D0-907-553-V2.clb
   Part No: 3D0 907 553 C
   Component: LUFTFDR.-CDC- 3C3V0 1122  
   Coding: 0005521
   Shop #: WSC 01065 000 00000
   VCID: 275DB73395D2CE063C-5140

No fault code found.
-------------------------------------------------------------------------------
Address 37: Navigation        Labels: 3D0-919-887.lbl
   Part No: 3D0 919 887 J
   Component:    NAVIGATION       0188  
   Coding: 0400000
   Shop #: WSC 01065 000 00000
   VCID: 3B757B43795A7AE648-515E

No fault code found.
-------------------------------------------------------------------------------
Address 38: Roof Electronics        Labels: 3D0-907-135.lbl
   Part No: 3D0 907 135 C
   Component: Dachmodul           0708  
   Coding: 0000044
   Shop #: WSC 01065 000 00000
   VCID: 2345A323E1EA222660-5140

No fault code found.
-------------------------------------------------------------------------------
Address 39: Right Light        Labels: 3D0-909-158.lbl
   Part No: 3D0 909 158 A
   Component: EVG GDL+AutoLWR(r)  0001  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 285FB40F98CCC17E35-515E

No fault code found.
-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 3D0-959-933.lbl
   Part No: 3D0 959 933 F
   Component: X3 HSG              0102  
   Coding: 0000034
   Shop #: WSC 01065 000 00000
   VCID: 33655363510AB2A690-4AE8

   Subsystem 1 - Part No: 3D2 959 701 H
   Component: Tuersteuergeraet FS 0201

   Subsystem 2 - Part No: 3D2 959 702 H
   Component: Tuersteuergeraet BF 0201

   Subsystem 3 - Part No: 3D0 959 703 G
   Component: Tuersteuergeraet HL 0201

   Subsystem 4 - Part No: 3D0 959 704 G
   Component: Tuersteuergeraet HR 0201

   Subsystem 5 - Part No: 7L0 907 719 A
   Component:    Neigungssensor   0020

No fault code found.
-------------------------------------------------------------------------------
Address 47: Sound System        Labels: 7Lx-035-4xx-47.lbl
   Part No: 3D0 035 465 A
   Component: 08K-AUDIOVERST      0112  
   Shop #: WSC 00000 000 00000
   VCID: 1F4DAFD3CD8206C644-5140

1 Fault Found:
00874 - Treble Speaker Front Left (R20) 
            011 - Open Circuit
-------------------------------------------------------------------------------
Address 68: Wiper Electr.        Labels: 3Dx-955-1xx-V1.clb
   Part No: 3D2 955 120 A
   Component: Front Wiper         3000  
   Shop #: WSC 00000 000 00000
   VCID: 204FAC2FF0FC393E7D-5140

No fault code found.
-------------------------------------------------------------------------------
Address 71: Battery Charger        Labels: 3D0-915-181.lbl
   Part No: 3D0 915 181 D
   Component: Batteriemanagement  2800  
   Shop #: WSC 00000 000 00000
   VCID: 2447A03FE4E4251E19-5140

No fault code found.
-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: None
   Part No: 3D0 919 283 D
   Component: 01 Einparkhilfe     0907  
   Shop #: WSC 00000 000 00000
   VCID: 2B554B03893AEA66D8-5140

No fault code found.
End-------------------------(Elapsed Time: 08:06)--------------------------

SRI Report

Mileage: 69775   Repair Order: 12/11/15

VCDS Release 15.7.1:  SRI Reset
Control Module Part Number: 3D0 920 982 H       Labels:  3D0-920-xxx-17.lbl
Component:KOMBIINSTRUMENT RB8 0610, Coding:0023411
Operation: Please select an operation
****************************************************************************************************************
Channel  	Description                                       	Unit      	Current val.  	New val.  
02       	Service Reminder Status                           	          	0             	---       
40       	Mileage since Service                             	km x100   	103           	---       
41       	Time since Service                                	Days      	466           	---       
42       	Min Mileage to Service                            	km x100   	15            	---       
43       	Max Mileage to Service                            	km x100   	30            	---       
44       	Max Time to Service                               	Days      	730           	---       
45       	Oil Quality                                       	          	4             	---       
47       	Soot Quantity                                     	km x100   	58            	---       
48       	Thermal Load                                      	km x100   	60            	---       
49       	Min Time to Service                               	---       	---           	---       
****************************************************************************************************************

Measurement Blocks

           Address 01: Engine  (3D0 907 401 A)

16:01:10 Group 104: Diesel Particle Filter (DPF)
  0.20  Particle Filter Oil Ash Volume
  58.5  Particle Filter Carbon Mass (calc.)
  35.4  Particle Filter Carbon Mass (act.)
  2120 km  Mileage 

16:01:10 Group 107   DID NOT RESPOND!
        
15:54:36 Group 037
  0 /min  RPM 
  20.5 %  Duty Cycle 
  89.2 %  Duty Cycle 
  0.0 mg/str  Mass Air / Rev.


          Address 71: Battery Charger  (3D0 915 181 D)

15:44:22 Group 001: Voltages Present
  12.65 V  Term 15 (Ignition) (start relevant)
  12.65 V  Terminal 30 (start relevant)
  12.65 V  Terminal 30 (Comfort battery)
  13.37 V  Terminal 30 (starter battery)


Hope someone can help.

Regards

Ray
 
   #2  

Jack@European_Parts

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Start with addressing the faults as per the repair manual and WD.

Visually inspect,and or manually clean the needed hardware.
 
   #3  

Rayston

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Start with addressing the faults as per the repair manual and WD.

Visually inspect,and or manually clean the needed hardware.

Hi,

Thanks for the response. Unfortunately my repair manual (ElsaWin 4.1) doesn't show much detail on Throttle Valve Controller or which fuse I need to check for the V275 motor wiring. I've also looked at SPP 272 & 350 but am still none the wiser! :(

Do the stat's shown in the scans suggest a DPF regen' is needed?
Do I need engine warmed up and running for these scans?
Have I used the right Measurement blocks?
Do you know if there is a step by step guide for checking faults 004120, 005445 and 009263?
If I can rule out electrics first, I was then planning on stripping and cleaning Throttle Valve; is that the way to go?

Thanks for your help

Ray
 
   #6  

Rayston

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Latest update.

Spent a day on Erwin and although I gleaned a lot of info' it didn't give me what I was hoping for and I had the impression that using and paying for the "Diagnostics" access would not have worked with my VCDS. I had hoped to have access to the "Guided Repair" facility but couldn't find that so I decided to press on with what I had.

I tried to check fuse SD1 in the Electrics Box in the Plenum Chamber.......I need a tame worm to go in there for me.:) Considering it's such a big car, it's incredible that access is so tight!

Anyway, gave up on that and went on to check/clean the throttle valve (J338). It was pretty mucky in there but not baked on. Flap movement however was very notchy so I guessed the gears might be damaged and further investigation showed this to be the case. I can't believe that fragile plastic gears were used in a component that is in constant use in a hot dirty environment.:mad: The gears can't be bought separately and I don't have the skill or the facilities to make them, so it's a full unit at £430 from VW or £180 from Germany on e-bay.....no contest then!

I believe the ACV has been improved over the years and not before time, so when the new one arrives I'm inclined to re-assemble and calibrate and then re-scan to see if I still need to repair/replace the swirl flaps on the intake manifold. Strangely, the fault shows as Bank 2 (left yes?) but on switch on, that one cycles only once whereas the right hand cycles twice suggesting it's not happy!:confused:

I'm hoping that the flashing MIL and limp mode will have cleared. Watch this space!!

R
 
   #9  

Rayston

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Update 2

New throttle valve (J338) arrived from Germany on Saturday, pristine and sealed in VDO box. Fitted it today but unsure as to whether adaptation is needed or not??? :(

Scan shows that fault 005445/P1545 has cleared, 'though I haven't started the car yet until I can be certain on adaptation??? Anyone know of a definitive step by step guide for greenhorns???

Sadly the other two faults still show, 004120 and 009263, and the glo-plug indicator still flashes even though the DPF warning light remains off. :confused:

If I can sort this adaptation, I'll scan again before perhaps trying chemical decarburization and/or a forced DPF regeneration. Failing that, I guess it's strip the intake manifold and do the swirl flaps.

Any pointers would be much appreciated.

Thanks.

R
 
   #10  

Rayston

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Update 3

Hi,

Tried adaptation using Group 060 but didn't get the expected response. Read on Audi forum that ACV does not need adaptation on TDI, so with some trepidation I started the engine. It started well, ran smoothly with good throttle response and no judder on shutdown so I assume new valve is OK. Fault 005445/P1545 has cleared but I still have 004120/P1018 and 009263/P242F with the flashing glowplug. I'm concerned about taking the car out to warm up and check limp mode, as MWB 104.2 shows 58 already even though the DPF light is not on. Also OBD2 fault on inlet manifold shows P2011 electrical malfunction! Could previous boot (trunk) electrics problem have any impact on this?

Where do I go from here???

R
 
   #11  

Jack@European_Parts

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Neu auto-scan please ..........

Der kluge ZJak

Time for DPF remediation..............and

17426/P1018/004120 - Intake Manifold Runner (Bank 2): Lower Limit not reached [h=4]Possible Symptoms[/h]
  • Malfunction Indicator Light (MIL) ON
[h=4]Possible Causes[/h]
  • Fuse(s) faulty
  • Wiring and/or Connector(s) from/to Intake Manifold Runner Motor 2 (V275) faulty
  • Intake Manifold Runner Motor 2 (V275) faulty
  • Intake Manifold Flap 2 faulty
[h=4]Possible Solutions[/h]
  • Check Fuse(s)
  • Check Wiring and/or Connector(s) from/to Intake Manifold Runner Motor 2 (V275)
  • Check/Replace Intake Manifold Runner Motor 2 (V275)
  • Check Linkage between Intake Manifold Runner Motor 2 (V275) and Intake Manifold Flap 2 Movement, Rust and when necessary use Lubricants to repair it. If the Flap is still sluggish, also lubricate the Flap Bearings.
  • Check/Replace Intake Manifold Flap 2
 
   #12  

Rayston

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Neu auto-scan please ..........

Der kluge ZJak

Time for DPF remediation..............and

Hi Jack,

Thanks again for responding. I'm posting the latest scan, as requested, along with a few other details. Sorry about the delay but I found a broken wire in the trunk harness which took a while to sort. Turned out to be a red herring though as it was just a reversing light!

Anyway, scan still shows two faults on the engine and my main concern is whether I can get to a regen' of the DPF before I sort the swirl flap "electrical malfunction" ?

DPF Group 104.2 shows this development:-

56.7 on 02/11/15 @ 69748 miles
58.5 on 12/11/15 @ 69773 miles after a warm-up run to attempt forced DPF regen'
58.8 on 14/12/15 @ 69773 miles following static run of motor after fitting new ACV

I read somewhere that if this gets to 59.5, the DPF is a write off and has to be replaced. Is that right?

I'd really appreciate some guidance as to how to proceed from here, hopefully without having to spend mega-bucks on a new DPF.

If I need to sort the 004120/P1018 first, is it likely to be electrical as indicated by P2011 from Mode 3 & 7 below? Both motors and swirl flaps appear to be operating freely on switch on and by depressing the push rods manually. Unfortunately, if it is electrical, all my diagrams/layouts seem to be for LHD cars whereas mine is RHD so I'm working in the dark a bit!!!

Code:
Monday,14,December,2015,20:12:47:16346
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 15.7.2.0 (x64)
Data version: 20151124
www.Ross-Tech.com

Mileage: 112290km-69773mi   Repair Order: 14/12/15
--------------------------------------------------------------------------------
--------------------------------------------------------------------------------
Chassis Type: 3D (3D - VW Phaeton (2002 > 2006))
Scan: 01 02 03 05 06 07 08 09 11 13 15 16 17 18 19 23 27 28 29 2E
          34 36 37 38 39 46 47 55 56 57 65 66 68 69 71 75 76 77
 
VIN: WVWZZZ3DZ78001243   Mileage: 112290km-69773miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 059-907-401-ASB.clb
   Part No SW: 3D0 907 401 A    HW: 8E0 907 401 AB
   Component: 3.0L V6TDI  G000AG  0010  
   Revision: --H01---    Serial number: VWZ3Z0F1504912
   Coding: 0011773
   Shop #: WSC 01065 000 00000
   VCID: 1D3195DBC78E14D660-5140

2 Faults Found:
004120 - Intake Manifold Runner (Bank 2) 
               P1018 - 001 - Lower limit not reached
             Freeze Frame:
                    Fault Status: 01100001
                    Fault Priority: 0
                    Fault Frequency: 8
                    Reset counter: 255
                    Mileage: 112293 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Torque: 249.6 Nm
                    Speed: 0.0 km/h
                    Voltage: 12.77 V
                    Duty Cycle: 20.5 %
                    Duty Cycle: 89.2 %
                    Duty Cycle: 20.5 %

009263 - Diesel Particulate Filter (Bank 1) 
               P242F - 001 - Restricted/Clogged - MIL ON
             Freeze Frame:
                    Fault Status: 11100001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 112293 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Torque: 249.6 Nm
                    Speed: 0.0 km/h

Readiness: 1 2 0 1 1 
-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 09L-927-760.lbl
   Part No SW: 09L 927 760 J    HW: GS1 9.1 1.4 
   Component: AG6 09L 3.0lTDI RdW 2205  
   Revision: 00000001    Serial number:        4218860
   Coding: 0000001
   Shop #: WSC 00000 000 00000
   VCID: 3E7372576A486FCE59-5140

No fault code found.
-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 3D0-614-517.lbl
   Part No: 3D0 614 517 AK
   Component: ESP 5.7 allrad  H33 0047  
   Coding: 0008356
   Shop #: WSC 01065 000 00000
   VCID: 6BD58B0349BA2A66AE-5124

No fault code found.
-------------------------------------------------------------------------------
Address 05: Acc/Start Auth.        Labels: 3D0-909-13x-05.lbl
   Part No SW: 3D0 909 139     HW: 5WK 484 94
   Component: 0C Kessy            6700  
   Revision: 67006015    Serial number: VWZ3Z0F1504912
   Coding: 0004328
   Shop #: WSC 01065 000 00000
   VCID: 66C3FA375258170EF1-5140

   Subsystem 1 - Part No: XXXXXXXXXXX 
   Component: ELV                 XXXX

No fault code found.
-------------------------------------------------------------------------------
Address 07: Control Head        Labels: 3D0-035-00x-07.lbl
   Part No: 3D0 035 007 AR
   Component:    ZAB COCKPIT      0253  
   Coding: 0400405
   Shop #: WSC 01065 000 00000
   VCID: 69D9F10B43463876DC-5140

No fault code found.
-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3D0-907-040.lbl
   Part No: 3D0 907 040 J
   Component: Climatronic D1      2031  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 2541BD3BEFDEDC1638-515E

No fault code found.
-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3D0-937-049-V2.clb
   Part No SW: 3D0 937 049 L    HW: 3D0 937 049 L
   Component: J519                6200  
   Revision: -4003---    Serial number: --------------
   Coding: 600100002A211D000000000000000000
   Shop #: WSC 00490 210 84717
   VCID: 33655363510AB2A6A6-5140

No fault code found.
-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 3D0-909-601.lbl
   Part No: 3D0 909 601 E
   Component: 0H Airbag 8.4E+ H10 0935  
   Coding: 0012360
   Shop #: WSC 01065 000 00000
   VCID: 2541BD3BEFDEDC1638-5140

No fault code found.
-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 3D0-953-549.lbl
   Part No: 3D0 953 549 D
   Component: Lenksäulenmodul     3401  
   Coding: 0000031
   Shop #: WSC 01065 000 00000
   VCID: 2E534217BA289F4EC9-5140

No fault code found.
-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 3D0-920-xxx-17.lbl
   Part No: 3D0 920 982 H
   Component: KOMBIINSTRUMENT RB8 0610  
   Coding: 0023411
   Shop #: WSC 01065 000 00000
   VCID: 2D51451BB72EE456F0-515E

No fault code found.
-------------------------------------------------------------------------------
Address 18: Aux. Heat        Labels: None
   Part No: 3D0 815 005 AG
   Component: Standheizung        2426  
   Shop #: WSC 01065 000 00000
   VCID: 62CBE627BE706B2E1D-5140

No fault code found.
-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<>CAN      0101  
   Coding: 0000006
   Shop #: WSC 01065 000 00000
   VCID: 70EF9C6F609CC9BE9B-5140

No fault code found.
-------------------------------------------------------------------------------
Address 29: Left Light        Labels: 3D0-909-157.lbl
   Part No: 3D0 909 157 A
   Component: EVG GDL+AutoLWR(l)  0001  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 275DB73395D2CE060A-5140

No fault code found.
-------------------------------------------------------------------------------
Address 34: Level Control        Labels: 3D0-907-553-V2.clb
   Part No: 3D0 907 553 C
   Component: LUFTFDR.-CDC- 3C3V0 1122  
   Coding: 0005521
   Shop #: WSC 01065 000 00000
   VCID: 275DB73395D2CE060A-5140

No fault code found.
-------------------------------------------------------------------------------
Address 37: Navigation        Labels: 3D0-919-887.lbl
   Part No: 3D0 919 887 J
   Component:    NAVIGATION       0188  
   Coding: 0400000
   Shop #: WSC 01065 000 00000
   VCID: 3B757B43795A7AE67E-5140

No fault code found.
-------------------------------------------------------------------------------
Address 38: Roof Electronics        Labels: 3D0-907-135.lbl
   Part No: 3D0 907 135 C
   Component: Dachmodul           0708  
   Coding: 0000044
   Shop #: WSC 01065 000 00000
   VCID: 2345A323E1EA222656-5140

No fault code found.
-------------------------------------------------------------------------------
Address 39: Right Light        Labels: 3D0-909-158.lbl
   Part No: 3D0 909 158 A
   Component: EVG GDL+AutoLWR(r)  0001  
   Coding: 0000001
   Shop #: WSC 01065 000 00000
   VCID: 285FB40F98CCC17E03-515E

No fault code found.
-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 3D0-959-933.lbl
   Part No: 3D0 959 933 F
   Component: X3 HSG              0102  
   Coding: 0000034
   Shop #: WSC 01065 000 00000
   VCID: 33655363510AB2A6A6-4B00

   Subsystem 1 - Part No: 3D2 959 701 H
   Component: Tuersteuergeraet FS 0201

   Subsystem 2 - Part No: 3D2 959 702 H
   Component: Tuersteuergeraet BF 0201

   Subsystem 3 - Part No: 3D0 959 703 G
   Component: Tuersteuergeraet HL 0201

   Subsystem 4 - Part No: 3D0 959 704 G
   Component: Tuersteuergeraet HR 0201

   Subsystem 5 - Part No: 7L0 907 719 A
   Component:    Neigungssensor   0020

No fault code found.
-------------------------------------------------------------------------------
Address 47: Sound System        Labels: 7Lx-035-4xx-47.lbl
   Part No: 3D0 035 465 A
   Component: 08K-AUDIOVERST      0112  
   Shop #: WSC 00000 000 00000
   VCID: 1F4DAFD3CD8206C672-5140

1 Fault Found:
00874 - Treble Speaker Front Left (R20) 
            011 - Open Circuit
-------------------------------------------------------------------------------
Address 68: Wiper Electr.        Labels: 3Dx-955-1xx-V1.clb
   Part No: 3D2 955 120 A
   Component: Front Wiper         3000  
   Shop #: WSC 00000 000 00000
   VCID: 204FAC2FF0FC393E4B-5140

No fault code found.
-------------------------------------------------------------------------------
Address 71: Battery Charger        Labels: 3D0-915-181.lbl
   Part No: 3D0 915 181 D
   Component: Batteriemanagement  2800  
   Shop #: WSC 00000 000 00000
   VCID: 2447A03FE4E4251E2F-515E

No fault code found.
-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: None
   Part No: 3D0 919 283 D
   Component: 01 Einparkhilfe     0907  
   Shop #: WSC 00000 000 00000
   VCID: 2B554B03893AEA66EE-5140

No fault code found.

End-------------------------(Elapsed Time: 08:08)--------------------------

OBD2 Readouts:-

Mode 07: Pending emission related fault codes

Address 10 (Engine): 2 Faults Found:
P2002 - Particulate Trap Bank 1: Efficiency Below Threshold
P2011 - Intake Manifold Flap; Bank 2: Electrical Malfunction
--------------------------------------------------------------------------------

Mode 03: Emission related fault codes

Address 10 (Engine): 2 Faults Found:
P2002 - Particulate Trap Bank 1: Efficiency Below Threshold
P2011 - Intake Manifold Flap; Bank 2: Electrical Malfunction
--------------------------------------------------------------------------------

Measurement Blocks:-

                Address 01: Engine  (3D0 907 401 A)

20:23:25 Group 102: Diesel Particle Filter (DPF)
  5.8°C  Temperature prior Precatalytic Converter
  11.8°C  Temperature 
  0.0 mbar  Particle Filter Different. Pressure
  11.8 mbar  Particle Filter Offset Different. Pressure

20:23:25 Group 103
  0.0  (no units) 
      1001  Bin. Bits 
  714.0  (no units) 
        00  Bin. Bits 

20:23:25 Group 104: Diesel Particle Filter (DPF)
  0.20  Particle Filter Oil Ash Volume
  58.8  Particle Filter Carbon Mass (calc.)
  0.0  Particle Filter Carbon Mass (act.)
  2120 km  Mileage 
--------------------------------------------------------------------------------

                Address 71: Battery Charger  (3D0 915 181 D)

20:34:01 Group 001: Voltages Present
  12.29 V  Term 15 (Ignition) (start relevant)
  12.36 V  Terminal 30 (start relevant)
  12.29 V  Terminal 30 (Comfort battery)
  12.65 V  Terminal 30 (starter battery)

20:34:01 Group 002: Current Demands
  0.0 A  Current Term 15 (Ignition)
  0.0 A  Current Term 30 (Battery)
  10.0°C  Battery compartment temperature
  11.0°C  Internal battery  temperature

20:34:01 Group 003: Digital inputs
  Term 15 On  Digital input Term 15 (Ignition)
  Term 50 Off  Digital input Term 50 (Starter)
  ON  Digital input Key In
--------------------------------------------------------------------------------

                Address 34: Level Control  (3D0 907 553 C)                                                                        (Aaaaghh!!! More of which later!!! :-()

20:43:11 Group 004: Deviation from Nominal Vehicle Height
  -28.0 mm  Left Front Height Deviation
  -70.0 mm  Right Front Height Deviation
  13.0 mm  Left Rear Height Deviation
  -7.0 mm  Right Rear Height Deviation

20:43:11 Group 005: Absolute Vehicle Height
  101.0  Left Front (G78) Absolute Height
  63.0  Right Front (G289) Absolute Height
  129.0  Left Rear (G76) Absolute Height
  109.0  Right Rear (G77) Absolute Height

20:43:11 Group 006: Compressor
  9.0°C  Compressor Temp. (G290)
  6.18 bar  Reservoir/Tank Pressure (G291)
  OFF  Drain/Relief Valve (N111)
  OFF  Accumulator Valve (N311)
--------------------------------------------------------------------------------

VCDS Release 15.7.2:  SRI Reset
Control Module Part Number: 3D0 920 982 H       Labels:  3D0-920-xxx-17.lbl
Component:KOMBIINSTRUMENT RB8 0610, Coding:0023411
Operation: Please select an operation
************************************************************************************************************************
Channel  	Description                                       	Unit      	Current val.  	New val.  
02       	Service Reminder Status                           	          	0             	---       
40       	Mileage since Service                             	km x100   	103           	---       
41       	Time since Service                                	Days      	498           	---       
42       	Min Mileage to Service                            	km x100   	15            	---       
43       	Max Mileage to Service                            	km x100   	30            	---       
44       	Max Time to Service                               	Days      	730           	---       
45       	Oil Quality                                       	          	4             	---       
47       	Soot Quantity                                     	km x100   	58            	---       
48       	Thermal Load                                      	km x100   	60            	---       
49       	Min Time to Service                               	---       	---           	---       
************************************************************************************************************************

Thanks again in anticipation of your help.

Regards from across the pond!

Ray
 
   #13  

Jack@European_Parts

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I read somewhere that if this gets to 59.5, the DPF is a write off and has to be replaced. Is that right?

Manual cleaning of the DPF and intake + EGR is advised..........

This can be remediated by using chemicals on the car or remove everything for manual scrubbing.

No other short cuts I recommend, because the regen process at that level is a waste of time.

Oven cleaner with sodium hydroxide contained and distilled water rinse work the best.
 
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   #14  

Rayston

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Manual cleaning of the DPF and intake + EGR is advised..........

This can be remediated by using chemicals on the car or remove everything for manual scrubbing.

No other short cuts I recommend, because the regen process at that level is a waste of time.

Oven cleaner with sodium hydroxide contained and distilled water rinse work the best.


Groan!!! :( Unfortunately I don't have the facilities to handle that so I'm going to have to find somewhere to get it done. I hate handing my pride and joy over to others to work on!

Thanks again.

R
 
   #16  

Dex

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You can try, at your own risk, to reset value for calculated amount of soot (you usually do that after replacement of DPF). After that, you can start service regeneration (but you can damage DPF because of a lot of carbon in it, or even start a fire because of a high temperature). I would also replace G450, since the difference between measured, and actual amount of ash is too big.
 
   #17  

Rayston

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Thanks again Jack. A much cleaner solution than I anticipated. I'm also looking at the Bardahl cleaning process but have a feeling I need to sort the Intake Manifold Runner problem first, particularly if it is electrical as indicated by OBD2 P2011.

Regards

R
 
   #18  

Rayston

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You can try, at your own risk, to reset value for calculated amount of soot (you usually do that after replacement of DPF). After that, you can start service regeneration (but you can damage DPF because of a lot of carbon in it, or even start a fire because of a high temperature). I would also replace G450, since the difference between measured, and actual amount of ash is too big.

Hi Dex,

Ooooh! That sounds a bit too risky for me!!! I think I'm going to try sorting the 004120/P1018/P2011 problem first so that there are no faults showing apart from the DPF. Strange that the DPF warning light doesn't show, just the flashing glow plug.

Appreciate your input.

Regards

R
 
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