Problem with CJAA TDI swap into a 1991 GTI

   #1  

GTiTDi

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I swapped a CJAA TDI from a 2010 Jetta into my 1991 VW GTI that I had previously swapped a 1Z into around 2011. I completed the CJAA swap a couple years ago, however have had a persistent issue that I am seeking help with.

The car is driveable and the performance of an uncorked commonrail diesel in a light chassis is phenomenal, however when you try to drive any distance on the highway you end up with a flashing glow plug light and limp mode, until cycling the key. It immediately returns and you cannot procede further without repeatedly cycling the key and trying to feather the throttle to prevent it from going into limp again. Before this limp mode occurs the throttle control seems weird like you will have your foot steady on the pedal but the engine will speed up and down on its own like it doesn't know what to do. It is pretty alarming when it happens, it is not a subtle fluctuation. The codes that are generated when this occurs are the following. Mind you these codes only manifest themselves after one of these attempted cruises on the highway or when traveling in 4th 5th or 6th gear.

005000 - Control Module Malfunction - DBW Throttle Monitoring
P1388 - 007 - Short to Ground - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100111
Fault Priority: 2
Fault Frequency: 5
Mileage: 0 km
Time Indication: 0
Date: 2008.08.04
Time: 00:00:00
RPM: 2829 /min
Speed: 178.0 km/h
Voltage: 12.24 V
Voltage: 2.280 V
Voltage: 1.140 V
Torque: 1270.0 Nm

005000 - Control Module Malfunction - DBW Throttle Monitoring
P1388 - 000 - - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 5
Mileage: 0 km
Time Indication: 0
Date: 2008.08.04
Time: 00:00:00
RPM: 2829 /min
Speed: 179.0 km/h
Load: 50.6 %
Inj. Quantity: 0.0 mg/str
Hex Value: 0xFF00
Hex Value: 0xFF01
I have checked continuity and resistance from the 6 pin connector at the pedal and the T94 connector at the ECU. All seems fine. 5 volts at pins 1 and 2.

I am totally stumped.
 
   #2  

golfi_vend

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ECU is immo off I guess?

Please post full autoscan, even when ECU is only module.
 
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GTiTDi

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As requested, an autoscan. The trouble codes listed are for items that are not installed.

Code:
VIN: WVWNM7AJXBW000078

Chassis Type:1K
Scan: 01 02 03 08 09 0F 10 15 16 17 18 19 1C 22 25 2E 36 37 3D
         42 44 46 47 4F 52 55 56 57 62 65 69 72 76 77 7D

VIN: WVWNM7AJXBW000078



-----------------------------------------------------------------
Address 01: Engine      Labels: 03L-906-022-CBE.clb
        Part No SW: 03L 906 019 DA      HW: 03L906022TS
        Component: R4 2,0L EDC G001SG   7969
        Revision: 12H03---      Serial Number:               
        Coding: 0050072
        Shop #: WSC 01955 666 02675
        VCID: 6D9D5AB7242DEE46F654E6-8038

5 Faults Found:
001158 - Exhaust Gas Recirculation Sensor 2
        P0486 - 001 - Electrical Malfunction

001152 - Coolant Fan Control Circuit 1
        P0480 - 000 - Electrical Malfunction

012332 - Relay for Low Heater Output
        P302C - 000 - Short to Ground

001114 - EGR Valve 2 (N213)
        P045A - 000 - Electrical Malfunction

000321 - Oxygen (Lambda) Sensor B1 S2; Heating Circuit
        P0141 - 002 - Malfunction
 
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GTiTDi

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Moderators please move to appropriate forum please and thank you
 
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Uwe

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Moderators please move to appropriate forum please and thank you
Hmm... I'm not sure there is anyplace it really fits, but I suppose retrofits is the closest.

-Uwe-
 
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m87a

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Did you try to open throttle body and check teeth on gears?
 
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GTiTDi

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Did you try to open throttle body and check teeth on gears?

Is there even a possibility of this being an intermittent error? something you have seen before on a 2.0 CR TDI?
 
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m87a

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yes, often it it permanent dtc, couple of teeths shredded and it will immediately throw dtc but i had a case where one teeth was missing... worth checking
 
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MartinsX

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Code:
Address 01: Engine      Labels: 03L-906-022-CBE.clb
        Part No SW: 03L 906 019 DA      HW: 03L906022TS
        Component: R4 2,0L EDC G001SG   7969
        Revision: 12H03---      Serial Number:               
        Coding: 0050072
        Shop #: WSC 01955 666 02675
        VCID: 6D9D5AB7242DEE46F654E6-8038

5 Faults Found:
001158 - Exhaust Gas Recirculation Sensor 2
        P0486 - 001 - Electrical Malfunction

001152 - Coolant Fan Control Circuit 1
        P0480 - 000 - Electrical Malfunction

012332 - Relay for Low Heater Output
        P302C - 000 - Short to Ground

001114 - EGR Valve 2 (N213)
        P045A - 000 - Electrical Malfunction

000321 - Oxygen (Lambda) Sensor B1 S2; Heating Circuit
        P0141 - 002 - Malfunction
I think EGR DTC's will switch on limp mode anyway. You need to restore EGR system as it was originally. Or ask a tuner to remove everything EGR related from ECU software.
 
   #11  

Jetta 97

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Did you try to open throttle body and check teeth on gears?

This s TDI , there is no Throttle body . TDI has ASV which will not cause limp mode.

Code:
Address 01: Engine      Labels: 03L-906-022-CBE.clb
        Part No SW: 03L 906 019 DA      HW: 03L906022TS
        Component: R4 2,0L EDC G001SG   7969
        Revision: 12H03---      Serial Number:               
        Coding: 0050072
        Shop #: WSC 01955 666 02675
        VCID: 6D9D5AB7242DEE46F654E6-8038

5 Faults Found:
001158 - Exhaust Gas Recirculation Sensor 2
        P0486 - 001 - Electrical Malfunction

001152 - Coolant Fan Control Circuit 1
        P0480 - 000 - Electrical Malfunction

012332 - Relay for Low Heater Output
        P302C - 000 - Short to Ground

001114 - EGR Valve 2 (N213)
        P045A - 000 - Electrical Malfunction

000321 - Oxygen (Lambda) Sensor B1 S2; Heating Circuit
        P0141 - 002 - Malfunction
I think EGR DTC's will switch on limp mode anyway. You need to restore EGR system as it was originally. Or ask a tuner to remove everything EGR related from ECU software.
100% Agree. This is most likely root of the problem.
 
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   #12  

m87a

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you are correct it's not throttle body, but as i know it will cause limp mode?
 
   #13  

Jetta 97

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you are correct it's not throttle body, but as i know it will cause limp mode?

Only of is pedal faulty, but he said he checked it already.I never see ASV makes it to go in limp mode. This car has Electronic EGR at front of the intake as well , maybe you confusing this with it.
 
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m87a

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I know EGR will cause a limp mode but I was under impression that this will also cause limp mode... well you live to learn :)
 
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