2003, Golf MK4 GTi. Random cutting out and refusing to start

   #1  
Geelondon

Geelondon

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Hi all first off I hope I have the format for posting correct here.

I seem to have a car that will randomly cut out and refuse to start up. when attempting to start the car back up again its reluctant and requires gas pedal to the floor and continuous cranking.

the other issue I noticed was on some attempts there is just clicking and nothing more on trying to start it up. I have checked started motor etc and all is fine with there.

before I start swapping out the parts namely the N249 Valve or diverter valve is there any old hands that have experienced this issue and can shed light on any further tests.

many thanks in advance

Code: 
VIN: WVWZZZ1JZ3W603278   Mileage: 272430km-169280mi   


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: WVWZZZ1JZ3W603278   Mileage: 272430km-169280miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06A-906-032-AJQ.clb
   Part No: 06A 906 032 MJ
   Component: 1.8L R4/5VT     G   0003  
   Coding: 11510
   Shop #: WSC 00000  
   VCID: 72A8FFE93CE999160D-5160
   WVWZZZ1JZ3W603278     VWZ7Z0C7509285

2 Faults Found:
17608 - Boost Pressure Control Valve (N249) 
            P1200 - 35-10 - Mechanical Malfunction - Intermittent
16502 - Engine Coolant Temp. Sensor (G62) 
            P0118 - 35-00 - Signal too High
Readiness: 0000 1000

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ESP-F.lbl
   Part No: 1C0 907 379 M
   Component: ESP FRONT MK60      0102  
   Coding: 0019970
   Shop #: WSC 01271 785 00200
   VCID: 342439F1567DD726DF-5160

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl
   Part No: 3B1 907 044 C
   Component: CLIMATRONIC     C 2.0.0  
   Coding: 11000
   Shop #: WSC 01271  
   VCID: 210AC0A5A98F528E24-5184

2 Faults Found:
00792 - A/C Pressure Switch (F129) 
            35-00 - -
01274 - Air Flow Flap Positioning Motor (V71) 
            37-00 - Faulty

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 A
   Component: 27 AIRBAG VW51 01   0008  
   Coding: 12855
   Shop #: WSC 01271  
   VCID: 2208CFA9AC8949963D-513C

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1J0-907-487-A.lbl
   Part No: 1J0 907 487 B
   Component: Lenkradelektronik   0002  
   Coding: 00008
   Shop #: WSC 01271  
   VCID: 302C35E1F265EB06BB-5160

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J0 920 946 A
   Component: KOMBI+WEGFAHRSP VDO V13  
   Coding: 21414
   Shop #: WSC 00000  
   VCID: 2A182789D4B991D675-513C
   WVWZZZ1JZ3W603278     VWZ7Z0C7509285

1 Fault Found:
01316 - ABS Control Module 
            49-10 - No Communications - 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 01271  
   VCID: 70ACF5E132E5AB06FB-513C

1 Fault Found:
01316 - ABS Control Module 
            49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 B
   Component: 1X Komfortgerát HLO 0003  
   Coding: 00258
   Shop #: WSC 01271  
   VCID: 362003F91001C536E1-4B1E

   Subsystem 1 - Part No: 1C2959802A
   Component: 1X Tõrsteuer.FS KLO 0009  

   Subsystem 2 - Part No: 1C2959801A
   Component: 1X Tõrsteuer.BF KLO 0009  

   Subsystem 3 - Part No: 1C0959811A
   Component: 1X Tõrsteuer.HL KLO 0009  

   Subsystem 4 - Part No: 1C0959812A
   Component: 1X Tõrsteuer.HR KLO 0009  

1 Fault Found:
00930 - Locking Module for Central Locking; Rear Left (F222) 
            27-00 - Implausible Signal

End----------(Elapsed Time: 04:47, VBatt start/end: 12.3V/12.3V)-----------
 
   #2  
T

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I can see G62 fault logged in your diagnosis...your problem sounds like over-enrichment or falsified air/fuel ratio caused by false engine temperature reported. If possible disconnect the G62 sender and retry or replace it, clear fault memory and recheck start-ability or post fresh scan.
 
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Jef

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If the starter isn't trying to engage, are you sure there is nothing wrong with it? How is the cable to comes off the battery to the starter? How is the Terminal 50 path for the starter (wiring rot, ignition switch melting)?

Also make sure ground points are good. Cable that bolts to top of transmission good. Ground points under battery tray. Ground point in plenum chamber. Odds are there is a ground point at the steering column and also ground points at the base of the A-pillars.
 
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Geelondon

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TFSI said:
I can see G62 fault logged in your diagnosis...your problem sounds like over-enrichment or falsified air/fuel ratio caused by false engine temperature reported. If possible disconnect the G62 sender and retry or replace it, clear fault memory and recheck start-ability or post fresh scan.
Click to expand...

I do have a temp switch on order so will give this a try .

what are your thoughts on N249 by pass ?
 
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Geelondon

Geelondon

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Jef said:
If the starter isn't trying to engage, are you sure there is nothing wrong with it? How is the cable to comes off the battery to the starter? How is the Terminal 50 path for the starter (wiring rot, ignition switch melting)?

Also make sure ground points are good. Cable that bolts to top of transmission good. Ground points under battery tray. Ground point in plenum chamber. Odds are there is a ground point at the steering column and also ground points at the base of the A-pillars.
Click to expand...

I have checked all earth points the gear box one was in poor state in fact just about holding on this has been replaced already but the problem still persists. will check the other points you mention thank you
 
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ai_Ingo

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There may be 2 failures or a cause with 2 effects. Like Jef said, it can be a bad ground. I think the screw connection is under the battery and on the gearbox.
Take a jump start cable, connect it to battery minus and the motor housing. So you can quickly make a diagnosis. Is the engine turning now? Second, there is the G62 temperature sensor, as described by TFSI. If the measured value deviates significantly from the actual value, the mixture is too rich, so that the engine only starts with gas and stutters, usually with a clearly black smoke. or on the other hand so lean that it doesn't start.
Remove the connector from the sensor, the control unit should use a substitute value.
 
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ECM defaults to -35C when the coolant temp sensor G62 goes open, just replace it. You can check the ECM freeze frame for this.

Check for bad battery as when voltage drops below 10 or so while cranking the starter relay can drop out causing your problem. A starter that draws too much amperage will also cause the primary circuit to drop out.
 
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ai_Ingo

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Fred's Imports said:
ECM defaults to -35C when the coolant temp sensor G62 goes open, just replace it. You can check the ECM freeze frame for this.

Check for bad battery as when voltage drops below 10 or so while cranking the starter relay can drop out causing your problem. A starter that draws too much amperage will also cause the primary circuit to drop out.
Click to expand...

Basically I agree with you, I've already seen -35 degrees. But this is a Bosch MED 7.5 system and I'm pretty sure that there is a substitute value for the temperature. Please have a look here: https://vwts.ru/forum/attachments/75039/
Page 67, there the strategy is described. But please, it's just my opinion, I can be wrong about that too.
 
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