Need Help with my 05 GTI

[gazaai]

Need help with my 05 GTI, cant rev it over 2k or else it backfires, engine jolts around a lot as well and wont hold boost.
I have several fault codes here in which I've tried changing the ECU, replaced Engine Wiring Loom & replaced Intake Manifold motor.
Codes are still present:

Code: [Select]

012691 - Intake Manifold Runner Control
               P3193 - 002 - Open Stop outside of Valid Range
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 173929 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:58:28

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 85.0°C
                    Temperature: 41.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 12.446 V

001602 - Sensor Reference Voltage A: Circuit
               P0642 - 002 - Low - MIL ON
             Freeze Frame:
                    Fault Status: 11100010
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 173929 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:58:28

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 85.0°C
                    Temperature: 41.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 12.446 V

004248 - Intake Manifold Tuning Valve Position Sensor (G336)
               P1098 - 001 - Open or Short to Plus
             Freeze Frame:
                    Fault Status: 01100001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 173929 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:58:28

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 85.0°C
                    Temperature: 41.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 12.446 V

012556 - Low Pressure Fuel Regulation
               P310C - 004 - Fuel Pressure Drops Intermittently
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 173929 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:58:55

             Freeze Frame:
                    RPM: 854 /min
                    Load: 19.2 %
                    Speed: 0.0 km/h
                    Temperature: 84.0°C
                    Temperature: 38.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 13.970 V

004917 - Engine Torque Monitor 2
               P1335 - 008 - Control Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00101000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 173953 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 18:29:42

             Freeze Frame:
                    RPM: 2606 /min
                    Load: 32.5 %
                    Speed: 106.0 km/h
                    Temperature: 96.0°C
                    Temperature: 18.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 14.351 V
Any help would be appreciated, Cheers

*** PROBLEM SOLVED ***

Problem is now solved, I had two failed sensors on the car:

• Low Fuel Pressure Sensor (06E 906 051 K) - Caused the Low Pressure Fuel Pump to run at 90% constantly.
• MAP Sensor (038 906 051 D) - Caused the intake manifold codes to be present, and car was unable to boost correctly.

How I found these faults:
By Logging the fuel preasure on VCDS I could see something was wrong:


The fuel pump was running at 90% consistently.
I tried the following to the car:

• New Fuel Line to Filter
• New Fuel Filter (correct 6.6 Bar one)
• New Low Pressure Fuel Pump

After this same again:


Next on the list was to try a New Low Fuel Pressure Sensor, after changing this it now looked like this:


This solved the issue with my fuelling causing a backfire, and I found the MAP Sensor to blame for the other intake manifold codes.

Hope this helps other people out

Fault Codes I had for anyone searching on google:

Code: [Select]

012691 - Intake Manifold Runner Control
               P3193 - 002 - Open Stop outside of Valid Range
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 174469 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:05:33

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 38.0°C
                    Temperature: 21.0°C
                    Absolute Pres.: 990.0 mbar
                    Voltage: 12.192 V

001602 - Sensor Reference Voltage A: Circuit
               P0642 - 002 - Low - MIL ON
             Freeze Frame:
                    Fault Status: 11100010
                    Fault Priority: 0
                    Fault Frequency: 6
                    Reset counter: 255
                    Mileage: 174469 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:05:33

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 38.0°C
                    Temperature: 21.0°C
                    Absolute Pres.: 990.0 mbar
                    Voltage: 12.192 V

004248 - Intake Manifold Tuning Valve Position Sensor (G336)
               P1098 - 001 - Open or Short to Plus
             Freeze Frame:
                    Fault Status: 01100001
                    Fault Priority: 0
                    Fault Frequency: 3
                    Reset counter: 255
                    Mileage: 174469 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 16:05:34

             Freeze Frame:
                    RPM: 2244 /min
                    Load: 23.1 %
                    Speed: 44.0 km/h
                    Temperature: 95.0°C
                    Temperature: 20.0°C
                    Absolute Pres.: 980.0 mbar
                    Voltage: 14.224 V

012555 - Low Pressure Fuel regulation
               P310B - 008 - Fuel Pressure Outside Specification
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 0
                    Fault Frequency: 9
                    Reset counter: 255
                    Mileage: 174469 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 17:00:26

             Freeze Frame:
                    RPM: 2075 /min
                    Load: 28.6 %
                    Speed: 29.0 km/h
                    Temperature: 83.0°C
                    Temperature: 18.0°C
                    Absolute Pres.: 990.0 mbar
                    Voltage: 13.970 V

000566 - Manifold Pressure / Boost Sensor (G31)
               P0236 - 008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 174524 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:21:12

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: 76.0°C
                    Temperature: 39.0°C
                    Absolute Pres.: 1010.0 mbar
                    Voltage: 12.319 V

004917 - Engine Torque Monitor 2
               P1335 - 008 - Control Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00101000
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 174527 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:24:52

             Freeze Frame:
                    RPM: 2585 /min
                    Load: 32.5 %
                    Speed: 105.0 km/h
                    Temperature: 82.0°C
                    Temperature: 15.0°C
                    Absolute Pres.: 1000.0 mbar
                    Voltage: 14.097 V

[stuart-88]

Just a stab in the dark but maybe the flaps themselves are clogged up with carbon, so not being able to physically move? Or highly unlikely but a faulty new motor?

[r5gtt]

I had the same a while back but once I cleared the fault a couple of times it stopped showing the fault. I've since bought the Runner flat delete but haven't fitted it in as yet. Clear fault drive a few days anc check again, if fault persists replace rf motor!.

[gazaai]

The faults won't clear just come back instantly without even starting the engine.

Already tried:
Changing ECU
Changing entire engine loom
Changing Flap motor

I really don't want to drive it for much longer like this. It even spits flames lol on gear changes, the pops don't sound healthy at all. Just waiting for it too bend a valve or something. I don't see a runner flap delete sorting this will it?

[r5gtt]

No the rdf won't resolve this issue.

Check these out mate

http://wiki.ross-tech.com/wiki/index.php/17026/P0642/001602

http://wiki.ross-tech.com/wiki/index.php/17506/P1098/004248

http://wiki.ross-tech.com/wiki/index.php/19649/P3193/012691

[gazaai]

Yeah I've had a look at those mate but it points to all the things I've already replaced 
Dunno what else is left to try

[r5gtt]

Was the motor anew part?.

Have you had injectors tested checked?

[gazaai]

Nah the motor was a used part but same part code. Do you think I should buy another and try it out?

No, I would rather get rid of these codes as I think it's to do with that. I mean the codes are here and won't go away even clearing them with engine off. So don't think injector related

[r5gtt]

Ive read on another  forum that it could well be an injector at fault but can't be 100% I'm afraid. Bucking could be a sign of a failed coil pack too. Check coil packs and plug for any usually burning.

[gazaai]

Well R8 coilpacks and NGK Irdiun spark plugs were just fitted 2k ago. Still have old ones in shed so might be worth a try. I just don't see how an injector would be related

[r5gtt]

If you're not getting enough fuel Coming through then it wil misfire. Hopefully someone in the know might be able to help but that's all I can think of mate.

Have a read of this

http://www.golfmkv.com/forums/showthread.php?t=184663
Good night

[gazaai]

Good night mate but the car ain't misfiring it's back firing on letting off throttle after using boost. Even spits flames lol

Definitely need to sort out these manifold codes first, might even need to take it to VW to see what they think.

[r5gtt]

Definitely sounds like fuelling issues if it's spitting out flames Over fuelling!.

https://m.youtube.com/watch?v=bgS3PA5r0vY

[gazaai]

Yeah but won't these faults be making it fuel the car wrong. That's why I'm trying to get rid of them first before I look into Fueling issues.

[r5gtt]

The car will obviously fuel wrong if backfire is evident.
Some say valve springs can be broken others say car may need decoking.
Get a compression test done to rule then out.
Have you tried driving with around with the air flow sensor off?.