I am going to day to borrow a vag-com to scan but until then, here is whats going on. Car was great all day yesterday, at night I got gas at a sunoco station and used 93 (93 was 3.63, 94 was 3.99), filled up about 3 gal. enough to get me home. 5 min into the drive, the engine starts sputting and dying, then goes into limp mode cause it was making no boost. when i came to a stop engine idled at about 500 rpm and that's when i noticed that if i rev it up above 1500 rpm, the engine dies until it drops below that then starts firing again. No apparent misfires, just dead after 1500 rpm. thought maybe bad gas, filled up alittle more at station closer to home. no change. actually now that i think about it, it will die after 1500 rpm for about 3 seconds and then start firing again, that is how i made it home, by keepng the revs higher. i didn't want to drive it like that but i was very close to home. ( i know i prob shouldn't have driven home like that, but i decided to anyway). I will post whatever the scan says but any insight would be great.

 

Bump. Please guys, any insight would be helpful. Please.

 

Failing fuel pump?

Gonna have to wait for a Vag and see what the codes are.

 

Uh Oh... Tried to vag scan the car, the other modules scan but the engine module won't scan, i get a "no response from controller message". Bad ECU? maybe, i am going to try to have it owed over to the guy who insoects it for me tomorrow, now i'm really confused.

 

Sounds like a fuel problem...

 

Check the connectors on the outside of the ECU GENTLY.

Possible bad chip solder the came loose internally? May have some work to find out.

 

Got it to scan, code is P1545 TP SENSOR FAILURE. Has any had this fail, what do i need to replace/fix, i will search on this also.

 

24-99


Throttle valve control module, checking
Note:

If the throttle valve control module -J338- is removed and installed, or replaced, adaptation of the throttle valve control module to the Motronic ECM is required Page 24-119 .

Required special tools and test equipment

VAG 1551 or VAG 1552 Scan Tool (ST) with VAG 1551/3 adapter cable

VAG 1598/22 test box

Multimeter US 1119 (Fluke 83 or equivalent)

VW 1594 connector test kit

Wiring diagrams




--------------------------------------------------------------------------------

24-100


Function

Idle speed stabilization is integrated in the throttle valve control module -J338-. In the housing opposite the throttle valve are Throttle Position (TP) sensor -G69-, Closed Throttle Position (CTP) switch -F60-, throttle drive -G186- and angle sensor -1- for throttle drive -G187-.

The housing should not be opened.

The individual components cannot be replaced or mechanically adjusted. All adjustments are accomplished by the VAG 1551 Scan Tool (ST) using the "Basic Setting" function 04.

If the complete throttle valve control module is without power (i.e. disconnected), the throttle valve assumes a mechanical closed throttle position that results in an increased idle speed of 1200-1300 RPM (with engine at operating temperature).

If only the Throttle Position (TP) actuator -V60- is without power, the throttle valve also assumes a mechanical closed throttle position (limp-home position), but because the signal from the CTP switch -F60- can still be recognized, a nearly "normal" idle speed of approx. 900 RPM is maintained with a corresponding reduction of the ignition timing advance.

If the Engine Control Module (ECM) recognizes a malfunction in the angle sensor -1- for throttle drive -G187-, it switches the power off for throttle drive -G186-,and the throttle valve again assumes the mechanical closed throttle position (limp-home position).




--------------------------------------------------------------------------------

24-101


Throttle valve control module power supply, checking

- Disconnect 8-pin harness connector from throttle valve control module -J338-.
- Connect multimeter US 1119 (Fluke 83 or equivalent) between harness connector terminals using adapter cables from VW 1594 connector test kit.
- Switch ignition on, and check voltage. Specified values:
Connector terminals 3 and 7 (Ground): 9.0-14.5 volts
Connector terminals 4 and 7 (Ground): 4.0-6.0 volts
- Switch ignition off.

If voltage is NOT OK:

- Connect VAG 1598/22 test box Page 01-56 .

- Check wiring for open circuit between ECM/test box and 8-pin harness connector.
Connector terminal 3 to ECM/test box socket 69
Connector terminal 4 to ECM/test box socket 62
Connector terminal 7 to ECM/test box socket 67
Specified value: max. 1.5




--------------------------------------------------------------------------------

24-102


- Check wiring for short circuit between ECM/test box and 8-pin harness connector.

Connector terminal 7 to ECM/test box socket 69

Connector terminal 7 to ECM/test box socket 62

Connector terminal 4 to ECM/test box socket 67

Specified value:

- Reconnect throttle valve control module harness connector.

If wiring is OK:

- Replace Motronic Engine Control Module (ECM) -J220- Page 01-57 .

- Carry out adaptation of throttle valve control module to ECM Page 24-119 .

- Check readiness code Page 01-59 . If Diagnostic Trouble Code (DTC) memory has been erased, or ECM was disconnected, generate new readiness code Page 01-62 .




--------------------------------------------------------------------------------

24-103


Closed Throttle Position (CTP) switch, checking

Note:

The Closed Throttle Position (CTP) switch -F60- is inside the throttle valve control module -J338-.

Test conditions

Throttle valve in closed throttle position; if necessary adjust accelerator pedal cable

Repair Manual , Fuel Supply System, Repair Group 20

Cruise control adjustment OK

Power supply for throttle valve control module OK; checking Page 24-101

Checking

- Connect VAG 1551 or VAG 1552 scan tool and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (with engine running at idle) Page 01-7 .

Rapid data transfer HELP

Select function XX

Indicated on display

- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input.

Read Measuring Value Block HELP

Input display group number XXX

Indicated on display




--------------------------------------------------------------------------------

24-104


- Press buttons -0-, -0- and -5- to input display group number 5, and press -Q- button to confirm input.

Read Measuring Value Block 5

1 2 3 4

Indicated on display (1-4 = display fields)

- Check Closed Throttle Position (CTP) switch (display field 4):


Display fields

1
2
3
4

Display group 5: Engine electronics

Display
xxx RPM
xx.xx ms
xxx km/h
Idle

Part throt

Full throt

Decel

Enrich

Indicates
Engine speed

(in 40 RPM steps)
Engine Load
Vehicle speed
Operational condition

Range
0-6800 RPM
0.00-8.50 ms
---
---

Specified value
760-960 RPM
0.50-1.50 ms
0 km/h
Throttle closed: "Idle"

Throttle slightly open: "Part throt"


---
---
---
If display is NOT OK Page 24-105 , Continuation





--------------------------------------------------------------------------------

24-105


Continuation

- Switch ignition off.

- Connect VAG 1598/22 test box to ECM harness connector Page 01-56 .

- Connect multimeter US1119 (Fluke 83 or similar) and check resistance between test box sockets 67and 69.

Specified value: max. 5.0

- Open throttle slowly. Specified value:

If resistance is NOT OK:

- Disconnect 8-pin harness connector for throttle valve control module -J338-.
- Check wiring for open circuit between ECM/test box and 8-pin harness connector.
Connector terminal 3 to ECM/test box socket 69
Connector terminal 7 to ECM/test box socket 67
Specified value: max. 1.5
- Check wiring for short circuit between ECM/test box and 8-pin harness connector.
Connector terminal 7 to ECM/test box socket 69
Specified value:




--------------------------------------------------------------------------------

24-106


- Reconnect throttle valve control module harness connector.

If wiring is OK:

- Replace throttle valve control module -J338-.

- Carry out adaptation of throttle valve control module to ECM Page 24-119 .

- Check readiness code Page 01-59 . If Diagnostic Trouble Code (DTC) memory has been erased, or ECM was disconnected, generate new readiness code Page 01-62 .




--------------------------------------------------------------------------------

24-107


Throttle drive and angle sensor for throttle drive, checking

Note:

Throttle drive -G186- and angle sensor -1- for throttle drive -G187- are located in the throttle valve control module -J338-.

Test conditions

Throttle valve in closed throttle position; if necessary adjust accelerator pedal cable

Repair Manual , Fuel Supply System, Repair Group 20

Cruise control adjustment OK

Power supply for throttle valve control module OK; checking Page 24-101

Engine coolant temperature at least 80C (176F)

Automatic transmission selector lever in "P" or "N"




--------------------------------------------------------------------------------

24-108


Checking

- Connect VAG 1551 or VAG 1552 scan tool and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (with engine running at idle) Page 01-7 .

Rapid data transfer HELP

Select function XX

Indicated on display

- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input.

Read Measuring Value Block HELP

Input display group number XXX

Indicated on display

- Press buttons -0-, -5- and -5- to input display group number 55, and press -Q- button to confirm input.

Read Measuring Value Block 55

1 2 3 4

Indicated on display (1-4 = display fields)




--------------------------------------------------------------------------------

24-109


- Compare display with specified values for idle air control (display fields 1-4):


Display fields

1
2
3
4

Display group 55: Idle control

Display
xxx RPM
x.xx g/s
x.xx g/s
xxxx

Indicates
Engine speed RPM

(in steps of 10 RPM)
Regulating value-idle mass air flow (idle air control)
Learning value-idle mass air flow
Operating conditions

Range
0-2550 RPM
-2.80 to 4.17 g/s
-1.94 to 2.22 g/s
---

Specified value
820-900 RPM
-1.11 to 1.11 g/s
-1.11 to 1.11 g/s
0000


If engine speed is NOT OK Page 24-111 , Continuation
If display is NOT OK Page 24-110 , Evaluating display group 55
Explanation Page 24-110


If displayed values are OK:

- Press button to advance program sequence.

- Press buttons -0- and -6- to select "End Output" function 06, and press -Q- button to confirm input.

- Switch ignition off.




--------------------------------------------------------------------------------

24-110


Evaluating display group 55

Display group: 55



Display fields: 2 3
Possible cause
Corrective action

above 1.11 g/s
Increased load because of switched-on consumers
Throttle valve mechanism sticking
Air passage in area of throttle valve contaminated
- Switch off electrical consumers



- Visually check, repair if necessary

below -1.11 g/s
Intake air leak (false air) behind throttle valve
- Check intake air system for leaks (false air) Page 24-97
- Check exhaust system:

Repair Manual , 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AEB, ATW, Repair Group 26


Explanation of the 4-digit display

Explanation when display field is = 0

x
x
x
x
(Display group 55)




0
A/C compressor off (0 = A/C compressor off /1 = A/C compressor on)



0

Shift lever in P or N (0 = Shift lever in P or N/ 1 = Shift lever in 2/3/4/R/D)


0


Always "0"

0



Always "0"





--------------------------------------------------------------------------------

24-111


Continuation

- Switch ignition off.

- Connect VAG 1598/22 test box to ECM harness connector Page 01-56 .

- Switch ignition on.

- With throttle valve in closed throttle position, connect multimeter US 1119 (Fluke 83 or equivalent), and check resistance between ECM/test box sockets 59 and 66.

Specified value: 3-200

If resistance is NOT OK:

- Disconnect 8-pin harness connector from throttle valve control module -J338-.

- Check wiring for open circuit between ECM/test box and 8-pin throttle valve control module harness connector.
Connector terminal 1 to ECM/test box socket 66
Connector terminal 2 to ECM/test box socket 59
Connector terminal 7 to ECM/test box socket 67
Connector terminal 8 to ECM/test box socket 74
Specified value: max. 1.5




--------------------------------------------------------------------------------

24-112


- Check wiring of 8-pin connector for short circuit between wires, according to wiring diagram.

Connector terminal 1 to ECM/test box socket 59

Connector terminal 1 to ECM/test box socket 74

Connector terminal 1 to ECM/test box socket 67

Connector terminal 2 to ECM/test box socket 67

Connector terminal 2 to ECM/test box socket 74

Connector terminal 7 to ECM/test box socket 74

Specified value:

If wiring is OK:

- Carry out adaptation of throttle valve control module to ECM Page 24-119 .

- Check readiness code Page 01-59 . If Diagnostic Trouble Code (DTC) memory has been erased, or ECM was disconnected, generate new readiness code Page 01-62 .




--------------------------------------------------------------------------------

24-113


Throttle Position (TP) sensor, checking

Note:

Throttle Position (TP) sensor -G69- is located inside the throttle valve control module -J338-.

Test conditions

Throttle valve in closed throttle position; if necessary adjust accelerator pedal cable

Repair Manual , Fuel Supply System, Repair Group 20

Cruise control adjustment OK

Power supply for throttle valve control module OK; checking Page 24-101

Checking

- Connect VAG 1551 or VAG 1552 scan tool and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (with ignition switched; engine not running) Page 01-7 .

Rapid data transfer HELP

Select function XX

Indicated on display

- Press buttons -0- and -8- to select "Read Measuring Value Block" function 08, and press -Q- button to confirm input.

Read Measuring Value Block HELP

Input display group number XXX

Indicated on display




--------------------------------------------------------------------------------

24-114


- Press buttons -0-, -0- and -3- to input display group number 3, and press -Q- button to confirm input.

Read Measuring Value Block 3

1 2 3 4

Indicated on display (1-4 = display fields)

- Compare display with specified values for throttle angle, (display field 3):


Display fields

1
2
3
4

Display group 3: Load measurement

Display
xxx RPM
xx.x g/s
xxx
xx.x BTDC

Indicates
Engine speed

(in 40 RPM steps)
Mass air flow
Throttle angle
Ignition timing

Range
0-6800 RPM
---
0-90
0.0-50.0BTDC

Specified value
0 RPM
---
0-5
0.0


---
---
If not as specified Page 24-115 , Evaluating display group 3
---


- Open throttle valve slowly while monitoring degree () value in display field 3.
Value must increase uniformly over the entire range.
- Press button to advance program sequence.



--------------------------------------------------------------------------------

24-115


- Press buttons -0- and -6- to select "End Output" function 06, and press -Q- button to confirm input.

- Switch ignition off.

Note:

The values displayed in display field 3 depend on the calibration of the Throttle Position (TP) sensor and do not correspond with the actual throttle valve opening in degrees. The maximum displayed value is 90.0 .

If the throttle angle value does not increase uniformly:

- Replace throttle valve control module -J338-.

- Carry out adaptation of throttle valve control module to ECM Page 24-119 .

- Check readiness code Page 01-59 . If Diagnostic Trouble Code (DTC) memory has been erased, or ECM was disconnected, generate new readiness code Page 01-62 .

Evaluating display group 3

Display group: 3



Display field: 3
Possible cause
Corrective action

0.0
Open circuit in wiring
- Check wiring Page 24-116

99.0
Short circuit to ground (GND)





--------------------------------------------------------------------------------

24-116


Checking wiring

- Connect VAG 1598/22 test box to ECM harness connector Page 01-56 .

- Connect multimeter US 1119 (Fluke 83 or equivalent), using adapter cables from VW 1594 connector test kit.

- Measure resistance to check for short circuit between test box sockets 2 (Ground) and 75 (signal wire).

Test box sockets 2 and 75

Specified value:

- Switch multimeter to voltage (20 VDC) measuring range.

- Switch ignition on.

- Check wiring for short circuit to B+.

Note voltage reading if applicable (if not 0 volts).

- Switch ignition off.

- Continue test, depending on whether or not voltage was measured Page 24-117 or Page 24-118 .




--------------------------------------------------------------------------------

24-117


Continuation (with measured voltage)

- Disconnect 8-pin harness connector from throttle valve control module -J338-.

If measured voltage was approx. 5 volts:

- Connect multimeter US 1119 (Fluke 83 or equivalent), using adapter cables from VW 1594 connector test kit.
- Measure resistance to check for short circuit between test box sockets 62 (power supply) and 75 (signal wire).
Test box sockets 62 and 75
Specified value:

If measured voltage was approx. battery positive voltage (B+):

- Check wiring at 8-pin connector, terminal 5 for short circuit to battery B+.




--------------------------------------------------------------------------------

24-118


Continuation (with no measured voltage)

- Disconnect 8-pin harness connector from throttle valve control module -J338-.

- Check wiring for open circuit between ECM/test box and 8-pin harness connector.
Connector terminal 5 to ECM/test box socket 75
Specified value: max. 1.5

If wiring is OK:

- Replace throttle valve control module -J338-.
- Carry out adaptation of throttle valve control module to ECM Page 24-119 .
- Check readiness code Page 01-59 . If Diagnostic Trouble Code (DTC) memory has been erased, or ECM was disconnected, generate new readiness code Page 01-62 .




--------------------------------------------------------------------------------

24-119


Throttle valve control module, adaptation to Engine Control Module (ECM)

If the throttle valve control module -J338- is removed and installed, or replaced, adaptation of the throttle valve control module to the Motronic ECM is required Page 24-119 .

During "adaptation" with ignition switched on and the engine not running, the Motronic ECM "learns" the closed throttle position (CTP), wide open throttle (WOT) and other positions of the throttle valve control module, and a characteristic curve of the relationship between Throttle Position (TP) sensor -G69- and angle sensor for throttle drive -G187-.

Required special tools and test equipment

VAG 1551 or VAG 1552 Scan Tool (ST) with VAG 1551/3 adapter cable

Test conditions

No malfunctions stored in DTC memory Page 01-15

Throttle valve in closed throttle position; if necessary adjust accelerator pedal cable

Repair Manual , Fuel Supply System, Repair Group 20

Cruise control adjustment OK

Power supply for throttle valve control module OK; checking Page 24-101




--------------------------------------------------------------------------------

24-120


Test procedure

- Connect VAG 1551 or VAG 1552 scan tool and press buttons -0- and -1- to insert "Engine Electronics" address word 01 (with ignition switched on; engine not running) Page 01-7 .

Rapid data transfer HELP

Select function XX

Indicated on display

- Press buttons -0- and -4- to select "Basic Setting" function 04, and press -Q- button to confirm input.

System in Basic Setting HELP

Input display group number XXX

Indicated on display

- Press buttons -0-, -6- and -0- to input display group number 60, and press -Q- button to confirm input.

System in Basic Setting 60

1 2 3 4

Indicated on display (1-4 display fields)

Note: After confirming input of display group 60, adaptation is started. The Throttle Position (TP)sensor is positioned in the closed throttle, wide open throttle and limp-home positions. Following this procedure, other intermediate steps will create a characteristic curve of the relationship between Throttle Position (TP) sensor -G69- and angle sensor for throttle drive -G187-.
The Motronic ECM stores these values in permanent memory. Afterward, the throttle valve assumes the starting position.





--------------------------------------------------------------------------------

24-121


- Compare display with specified values (display fields 1-4):


Display fields

1
2
3
4

Display group 60: Basic setting-throttle valve control module

Display
xxx
xxx
Idle

Part throt

Full throt

Decel

Enrich
ADP runs

ADP. OK

ADP. ERROR

Indicates
Throttle valve angle
Throttle drive angle
Operating condition
Adaptation condition

Range
0-90

---
---

Specified value
0-5

Idle
ADP. runs

ADP. OK

(ADP. ERROR indicates unsuccessful adaptation)


If displayed values are NOT OK:

- Check DTC memory ( Page 01-15 )
- Check throttle valve control module ( Page 24-99 )





--------------------------------------------------------------------------------

24-122


If displayed values are OK:

- Allow at least 30 seconds.

- End adaptation as soon as possible after 30 seconds by pressing button.

- Press buttons -0- and -6- to select "End Output" function 06, and press -Q- button to confirm input.



[IMG]local://upfiles/1947/A10A749166A3413AA360ED57CCEDF889.gif[/IMG]

[IMG]local://upfiles/1947/EE2845CCE18249F5B92BB99E2C84AF1C.gif[/IMG]

 

david9999 where do you get all that stuff? [:-]

 

seriously, is that like an online bently manual or something, thanks for all the info and for responding.