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Thread: Problem with CJAA TDI swap into a 1991 GTI

  1. #1
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    Problem with CJAA TDI swap into a 1991 GTI

    New to the forum

    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. #2
    Verified VCDS User golfi_vend's Avatar
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    ECU is immo off I guess?

    Please post full autoscan, even when ECU is only module.
    I am a VW Freak - Le WV Freaks OR Come visit me at my work with ODIS concerns - FORSS ODIS GeKo/FaZit access for VW/AUDI/Škoda
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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

  4. #4
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    Moderators please move to appropriate forum please and thank you

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    Benevolent Dictator Uwe's Avatar
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    Quote Originally Posted by GTiTDi View Post
    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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  6. #6
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    Anyone with any insight on this?

  7. #7
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    Did you try to open throttle body and check teeth on gears?
    There are 3 kind of services
    GOOD CHEAP FAST
    But you can only choose 2:
    GOOD and CHEAP won't be FAST
    FAST and GOOD won't be CHEAP
    CHEAP and FAST won't be GOOD

  8. #8
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    Quote Originally Posted by m87a View Post
    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?

  9. #9
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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
    There are 3 kind of services
    GOOD CHEAP FAST
    But you can only choose 2:
    GOOD and CHEAP won't be FAST
    FAST and GOOD won't be CHEAP
    CHEAP and FAST won't be GOOD

  10. #10
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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.

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