Need some help solving a engine problem

Tyrrell

Member
So just to explain what’s happened. We were all booked up for a 3 week trip around the alps had the van serviced clutch changed in preparation. Then the day before leaving took it for a drive and got a p0192 fault short gnd. It wasn’t running well at all. Started by checking the fuel pressure sensor wiring. 5v to power, gnd bleeped through to the negitave terminal. Signal wire was also ok. Un plugged the sensor and the fault changed to short to positive. So to me the fuel pressure sensor was at fault. Quickly went to the garage the next day they angreed it was the best place to start and they order in a new sensor. This was fitted and seemed to be back to normal I took it for a long drive and didn’t see any issues. Turned out they fitted an aftermarket sensor (I’ll come back to this)

Same day packed the van and set off it was driving fine under load but seems to hunt around trying to idle in traffic. Got to the campsite for the over night stop, did a search for the Symptoms and it seems to suggest others have had problems with after market sensors and have had to replace the with genuine vw parts as they struggle with the fluctuating low reading causing the idle speed fluctuations.

But it did sound they where able to drive there vans ok until they could replace the sensor. So decided to carry on with the trip. The plan being to pick one up when we got to the campsite in France as we are there for 5 nights. All was going well, still had there idle problem but it was intermittent. Got down to 1/4 of a tank of fuel so stopped to fill up. The van then would turn over but not start. (It had been running for 3.5hours) I did bring the vagcom with me scanned the van, no faults. Removed the plug to the fuel sensor just to eliminate the sensor and still didn’t start.Had to call for recovery, in the mean time while it cooled down thought I would remove the TDI tuning box just to eliminate that as well and it started. So have left that off. Managed to drive the next hour and a half to the campsite. It was still struggling to idle when we arrived. Got set up as it was Sunday into bank holiday Monday.
We are at chamonix the campsite the owner has offered to help (also a transporter owner) and has recommended a local vw garage.
So in my option I need to change the sensor for a genuine part to hopefully fix the idle. Still a bit puzzled why it didn’t start after filling up with fuel though, does anyone think that could be related to the sensor?

Sorry for the long post just though it would be easier to explain all that’s happened to far!
 
Please post
A) VCDS Auto-Scan​

Engine blockmap files
B) ignition on, engine off​
C) engine idling fluctuatingly​


How-to create a blockmap file:

[VCDS]
[Applications]
[Controller Channel Map]
- Single Controller Address = 01
- Login or security access code: Leave blank
- Function: Measuring values
- Output: CSV file
[Go]


The result files (.txt, .csv) are saved into directory C:\Ross-Tech\VCDS\Logs
 
i have 2 concerns the engine idle fluctuating which i think is related to the fuel pressure switch. The second being why it didnt start after i turned the engine off at the petrol station?
i did auto scan when the van wouldnt start with no faults showing. removing the fuel pressure switch connector in an attempt to rule that out did throw 1 faults which i have since cleared but they where p036 implausible signal then i think looking at the time line these 2 faults appeared after the tuning box was removed and the engine started p0088 too high, p0191 implausible signal. no more faults appeared in the drive to the campsite.
 
Just run the engine started straight away and idled ok, ran the log but it doesn’t seem to save to the same file location? Does it go some where else?
 
So just to update, the campsite owner rang the Volkswagen garage here and there not available until next Friday. The original plan was to be here until this Friday then move on to jungfrau campsite in Switzerland.
At the moment looks like it’s down to me. My current chain of thought is to get a genuine sensor ordered and sent to the camp site just in case. Would anyone be able to confirm the part number and what size socket is needed?
 
Last edited:
So just to update, the campsite owner rang the Volkswagen garage here and there not available until next Friday. The original plan was to be here until this Friday then move on to jungfrau campsite in Switzerland.
At the moment looks like it’s down to me. My current chain of thought is to get a genuine sensor ordered and sent to the camp site just in case. Would anyone be able to confirm the part number and what size socket is needed?
I have no idea but probably need year/model engine/van to find correct part number and tool size etc.

Good luck.
 
So I’ve managed to get the part number from tps in the uk. 03L 906 054A
I don’t suppose anyone might know the socket size I would need? I guess it’s a deep socket. Going to try to measure it here
 
So I’ve managed to get the part number from tps in the uk. 03L 906 054A
I don’t suppose anyone might know the socket size I would need? I guess it’s a deep socket. Going to try to measure it here
I could have a look on mine if it's easy to get to, '24 plate DNAA engine, don't know what you have ...
 
So I’ve managed to get the part number from tps in the uk. 03L 906 054A
I don’t suppose anyone might know the socket size I would need? I guess it’s a deep socket. Going to try to measure it here
From a photo online (LLL Parts) it looks like the electrical connector is very slightly smaller than the hex’ flats.
If it’s not the same as the aftermarket part you could make a pretty accurate guess based on the electrical connector size.
 
From a photo online (LLL Parts) it looks like the electrical connector is very slightly smaller than the hex’ flats.
If it’s not the same as the aftermarket part you could make a pretty accurate guess based on the electrical connector size.
Adjustable spanner ... depending on where the thing lives.
 
Looks like it’s a 27mm deep socket. Ideally 6 point. It doesn’t seem as easy to get parts here compared to the uk
 
Just run the engine started straight away and idled ok, ran the log but it doesn’t seem to save to the same file location? Does it go some where else?
Based on the posted scans, it seems you have got an old VCDS dongle. Unfortunately only newer (since 2017) VCDS HEX-V2 and VCDS HEX-NET cables have the capability to create blockmap files (of UDS protocol controllers which your ECU is).
 
yes it’s older than 2017. So with the being. No live faults and that it starts and runs. Could it be a heat soak issue where it was getting too hot?
I was going to ask if there was an away to check the fuel pumps with vcds. But where it has started from cold the tank pump must be working and secondary fuel pump I believe is the high pressure pump that kicks in at higher rpm. It ran fine for 1.5 hours after it had refused to start at the petrol station so I’m guessing that’s also ok.
 
Also just on a google search heat soak does seem to cause issues with the tuning boxes potentially stopping the van from starting. So that could be the the reason it wouldn’t start until the box was removed

IMG_1364.webp
 
I was going to ask if there was an away to check the fuel pumps with vcds.
Only for transfer fuel pump (in the tank), and auxiliary fuel pump (if installed).

Anyways, we could try see how high pressure pump & pressure sensor behave.

Please make a log of the following:
IDE00021 Engine RPM​
IDE00182 Camshaft adaptation intake bank 1: phase position​
IDE00188 Fuel high-pressure: actual value​
IDE00347 Air mass: actual value​
IDE00352 Main injection: duration of activation​
IDE00475 Fuel Pressure Regulator Valve​
IDE00476 Fuel Metering Valve​
IDE02228 Fuel pressure regulator valve: specified value rail pressure​
IDE03892 Fuel high pressure sensor: unconditioned voltage​
IDE04263 Sensor for particle filter differential press: raw value​
IDE04670 Crankshaft signal evaluation: status​

IGNITION ON
VCDS > Select > 01-Engine > Adv.Meas. Values
Tick the above mentioned data items​

Log > Start
Log 10 seconds (ignition on, engine off)​
Start the engine​
Log 30 seconds​
 
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