2006 AUDI A3 1.9TDI Conking oot

[A noddy]

Hi all, Help required, two weeks ago the car conked out after thought id put petrol in instead of diesel. I think i did so i got the car towed home , siphoned out the fuel ..under the back seat, changed the fuel filter and it started up , yeah i've fixed it i thought, my joy was short lived as it broke down and refused to start for 20 mins, It seems to cool down then start. I scanned it with vcds and got a fault on the glow plugs which i changed, same problem. it seems to get to 90 on the temp gauge and conk out .. i changed the thermostat today same blooming problem. Heater is still working so i'm hopefully ruling out the water pump. I left it running for an hour or so fine the fan came on briefly then off ..rads not Hot never Hot , couldn't resist, the bottom rad hose was still cool after an hour is this normal? scared to drive it....all or any advice greatly appreciated.

 

[Jezza16v]

Does it stop instantly like you turned it off or cough & splutter and die?

 

[A noddy]

It just dies . Battery light then stops ...leave it sitting for 10 -15 mins cranks over then a we cough it catches then keep turning the key it starts again no problems ? weird as .. I unhooked the water temp sensor so that the fans ran continuous and kept the temp down still died scanned it with no obvious errors

 

[A noddy]

Sunday,25,February,2018,16:32:49:09930
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 18.2.0.3 (x64)
Data version: 20180212 DS287.0
www.Ross-Tech.com


VIN: WAUZZZ8P06A193429 License Plate: YE06LKX 25/2/18
Mileage: 186490km-115879mi Repair Order:



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


Chassis Type: 8P (1K0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 47 52 56 62 72 7D

VIN: WAUZZZ8P06A193429 Mileage: 186490km-115879miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: Malfunction 0010
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: Malfunction 0010
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: Cannot be reached 1100
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
7D-Aux. Heat -- Status: Malfunction 0010

-------------------------------------------------------------------------------
Address 01: Engine Labels: 03G-906-016-BKC.clb
Part No SW: 03G 906 016 CC HW: 028 101 183 2
Component: R4 1,9L EDC G000SG 7999
Revision: 12345678 Serial number: AUX7Z0F2FNT0R4
Coding: 0000071
Shop #: WSC 06314 000 00000
VCID: 66C7E9D95141077482-8032

No fault code found.
Readiness: 0 0 1 1 1

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1K0-907-379-MK60-F.lbl
Part No SW: 1K0 907 379 AA HW: 1K0 907 379 AA
Component: ESP FRONT MK60 0102
Revision: 00H13001
Coding: 0021121
Shop #: WSC 06314 000 00000
VCID: 71ED8A85688FD0CCE7-8024

1 Fault Found:
00668 - Supply Voltage Terminal 30
002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 8P0-820-043.lbl
Part No SW: 8P0 820 043 M HW: 8P0 820 043 M
Component: KlimavollautomatH18 0260
Revision: 317820 Serial number: 8P0820043M
Shop #: WSC 06314 000 00000
VCID: 366779994161B7F4F2-8062

2 Faults Found:
00483 - Control Module for Auxiliary Air Heater
013 - Check DTC Memory
Freeze Frame:
Fault Status: 01101101
Fault Priority: 3
Fault Frequency: 1
Reset counter: 238
Mileage: 186447 km
Time Indication: 0
Date: 2000.00.00
Time: 01:31:20

Freeze Frame:
ON

00532 - Supply Voltage B+
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 1
Fault Frequency: 3
Reset counter: 18
Mileage: 186394 km
Time Indication: 0
Date: 2018.02.12
Time: 19:56:04

Freeze Frame:
Voltage: 9.00 V


-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 8P0-907-279-23-H.lbl
Part No SW: 8P0 907 279 F HW: 8P0 907 279 F
Component: Bordnetz-SG H43 1201
Revision: 00H43000 Serial number: 00000005584621
Coding: 01884F01B214100000160000160000000008FE175C0100
Shop #: WSC 06314 000 08192
VCID: 408B1F4113A5094458-8014

Subsystem 1 - Part No: 8P2 955 119 F Labels: 1KX-955-119.CLB
Component: Wischer AU350 H10 0040
Coding: 00056595
Shop #: WSC 06314

6 Faults Found:
01493 - Bulb for Blinkers; Front Left (M5)
012 - Electrical Fault in Circuit - Intermittent
Freeze Frame:
Fault Status: 00101100
Fault Priority: 2
Fault Frequency: 1
Reset counter: 19
Mileage: 186381 km
Time Indication: 0
Date: 2018.02.04
Time: 10:53:00

Freeze Frame:
ON
Voltage: 12.10 V
ON
ON
OFF
OFF
OFF

01497 - Bulb for Blinkers; Front Right (M7)
012 - Electrical Fault in Circuit - Intermittent
Freeze Frame:
Fault Status: 00101100
Fault Priority: 2
Fault Frequency: 8
Reset counter: 22
Mileage: 186181 km
Time Indication: 0
Date: 2018.01.24
Time: 22:22:00

Freeze Frame:
ON
Voltage: 14.45 V
ON
ON
OFF
OFF
OFF

02395 - Parking Light Front Right (M3)
012 - Electrical Fault in Circuit - Intermittent
Freeze Frame:
Fault Status: 00101100
Fault Priority: 2
Fault Frequency: 5
Reset counter: 22
Mileage: 186381 km
Time Indication: 0
Date: 2018.02.04
Time: 10:35:00

Freeze Frame:
ON
Voltage: 12.40 V
ON
ON
OFF
OFF
OFF

01500 - Bulb for Fog-Lamps; Right (L23)
010 - Open or Short to Plus
Freeze Frame:
Fault Status: 01101010
Fault Priority: 4
Fault Frequency: 5
Reset counter: 241
Mileage: 186381 km
Time Indication: 0
Date: 2018.02.11
Time: 10:04:00

Freeze Frame:
ON
Voltage: 11.60 V
ON
ON
OFF
OFF
OFF

01499 - Bulb for High-Beams; Right (M32)
010 - Open or Short to Plus - Intermittent
Freeze Frame:
Fault Status: 00101010
Fault Priority: 3
Fault Frequency: 3
Reset counter: 22
Mileage: 186381 km
Time Indication: 0
Date: 2018.02.04
Time: 10:35:00

Freeze Frame:
ON
Voltage: 12.40 V
ON
ON
OFF
OFF
OFF

00979 - Lamp for Low Beam; Right (M31)
010 - Open or Short to Plus - Intermittent
Freeze Frame:
Fault Status: 00101010
Fault Priority: 1
Fault Frequency: 4
Reset counter: 22
Mileage: 186381 km
Time Indication: 0
Date: 2018.02.04
Time: 10:35:00

Freeze Frame:
ON
Voltage: 12.40 V
ON
ON
OFF
OFF
OFF


-------------------------------------------------------------------------------
Address 15: Airbags Labels: 8P0-959-655-94.lbl
Part No SW: 8P0 959 655 C HW: 8P0 959 655 C
Component: Airbag 9.41 H12 3760
Revision: 91H12376 Serial number: 003620G03H15
Coding: 0071612
Shop #: WSC 06314 000 00000
VCID: 428F15491DA91B544E-8016

Subsystem 1 - Serial number: 6332DRB40311D29FR

Subsystem 2 - Serial number: 6342DRB403140D18E

Subsystem 3 - Serial number: 63528RB401222A568

Subsystem 4 - Serial number: 63628RB4012200F23

Subsystem 5 - Serial number: 63729RB4011DA750K

Subsystem 6 - Serial number: 63829RB4011DA44FW

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 8P0-953-549-F.lbl
Part No SW: 8P0 953 549 F HW: 8P0 953 549 F
Component: J0527 H34 0070
Coding: 0000042
Shop #: WSC 06314 000 00000
VCID: 418D1A4518AF004C57-8014

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 8P0-920-xxx-17-MY7.lbl
Part No SW: 8P0 920 981 B HW: 8P0 920 981 B
Component: KOMBIINSTR. VDO H80 0420
Revision: D06 Serial number: 2242FD06014425
Coding: 0004413
Shop #: WSC 00107 210 64237
VCID: 3779749D466B4EFCE9-8062

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels:. 1K0-907-530-V2.clb
Part No SW: 1K0 907 530 G HW: 1K0 907 951
Component: J533__Gateway H10 0140
Revision: H10 Serial number: 30001063118362
Coding: 3D3F0B4207002103
Shop #: WSC 06314 000 00000
VCID: 2B5158ED8A23FA1C9D-807E

1 Fault Found:
01304 - Radio
004 - No Signal/Communication
Freeze Frame:
Fault Status: 01100100
Fault Priority: 2
Fault Frequency: 254
Reset counter: 241
Mileage: 177299 km
Time Indication: 0
Date: 2016.05.21
Time: 08:25:47


-------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
Part No SW: 8P0 920 981 B HW: 8P0 920 981 B
Component: KOMBIINSTR. VDO H80 0420
Revision: D06 Serial number: AUX7Z0F2FNT0R4
Shop #: WSC 00847 210 80521
VCID: 3779749D466B4EFCE9-8062

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver Labels: 8P0-959-801-MAX2.lbl
Part No: 8P0 959 801 G
Component: Tuer-SG 020 0100
Coding: 0000688
Shop #: WSC 06314 000 00000
VCID: 3F891CBD6E5B76BC21-806A

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-144-G2V2.clb
Part No: 1K2 909 144 K
Component: EPS_ZFLS Kl.5 D06 1701
Shop #: WSC 00000 000 00000
VCID: 34634391571DA5E4CC-8060

1 Fault Found:
00446 - Function Limitation due to Under-Voltage
002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Mileage: 6360 km
Temperature: 16.0°C
Voltage: 6.00 V
Voltage: 5.80 V


-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 8P0-959-433.lbl
Part No: 8P0 959 433 C
Component: KSG H04 0050
Coding: 198000186D088505489FC63300
Shop #: WSC 00847 210 80521
VCID: 3C736BB17F4D6DA404-8068

Subsystem 1 - Part No: 1K0 951 605 C
Component: LIN BACKUP HORN H03 1301

Subsystem 2 - Part No: 1K0 907 719 C
Component: Neigungssensor 005 0003

Subsystem 3 - Part No: 8P0 951 177
Component: Innenraumueberw.H04 0020

No fault code found.

-------------------------------------------------------------------------------
Address 47: Sound System Labels: 8Px-035-382.lbl
Part No SW: 8P4 035 382 HW: 8P4 035 382
Component: AB2 SUBWOOFERBOXH04 0180
Revision: 00003 Serial number: 30674690371217
Shop #: WSC 00000 000 00000
VCID: 71ED8A85688FD0CCE7-8024

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. Labels: 8P0-959-802-MAX2.lbl
Part No: 8P0 959 802 G
Component: Tuer-SG 020 0100
Coding: 0000688
Shop #: WSC 06314 000 00000
VCID: 408B1F4113A5094458-8014

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio
Cannot be reached

-------------------------------------------------------------------------------
Address 62: Door, Rear Left Labels: 8P4-959-801.lbl
Part No: 8P4 959 801 D
Component: Tuer-SG 020 0070
Coding: 0000144
Shop #: WSC 06314 000 00000
VCID: 408B1F4113A5094458-8014

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right Labels: 8P4-959-802.lbl
Part No: 8P4 959 802 D
Component: Tuer-SG 020 0070
Coding: 0000144
Shop #: WSC 06314 000 00000
VCID: 418D1A4518AF004C57-8014

No fault code found.

-------------------------------------------------------------------------------
Address 7D: Aux. Heat Labels: 1K0-963-235.lbl
Part No SW: 1K0 963 235 E HW: 1K0 963 235 E
Component: PTC-Element 0404
Revision: 00800000 Serial number:
Shop #: WSC 00000 000 00000
VCID: 2D5556F5B437F42C83-8078

1 Fault Found:
00361 - Heater Element for Auxiliary Heater (Z35)
014 - Defective

End-------------------------(Elapsed Time: 01:50)--------------------------

 

[Jezza16v]

Does it stop first and then the battery light comes on or does the battery light come on and then it stops? You seem to have a lot of electrical issues from that printout? I wonder if something is causing a voltage drop to the ASV, if it shuts, the engine will stop immediately. Let the engine run until it stops again, while it is still hot, pop off the induction pipe just before the ASV, turn the ignition on (without starting the engine) and see if the ASV opens.

 

[A noddy]

Yeah it's battery light then stops won't turn over, should the flap be open or closed when the car is hot ? I remember my old A3 got gunked up and stuck closed and wouldn't start ..I'll take it off and clean it out anyway cheers

 

[Jezza16v]

The ASV should be open when the car is running or when you are starting it up, it only closes when you turn off the ignition, if it looses voltage it will shut and the car will stop. It should not be temperature related but as the car stops even when you hold the temperature down I suspect is an electrical issue especially if the battery light comes on just before it stops.

 

[A noddy]

I'll try stripping it off and cleaning it, I'm sure it stays open even with the ignition off. I'll check to see if I can cycle it using vcds. Cheers

 

[Jezza16v]

You are correct, the ASV is open when the engine is off, but at some point in the 'turning off' cycle it shuts to help stop the engine smoothly so I'm wondering if somehow it is shutting by itself when its not supposed to? If its shut while you are cranking the engine will not start.

 

[A noddy]

It's really frustrating I changed the thermostat and left it idling for about half an hour, it was fine as soon as I drove round the corner gave it some gas it chucked it refused to start sit for 10-20 mins it goes as if nothing happened cheers for your help !

 

[Jezza16v]

When it stops, try unplugging the 'coolant' temperature sender and then try starting it again. I have no idea where it is, just a suggestion from my son, he is a VW technician. He says when they won't start, they just try unplugging every sender, one at a time, and if it starts the one you just unplugged is the problem.

 

[A noddy]

Thanks Jezza for the advice I will give in plugging the sensors a go! I had a quick look and the ASV closes briefly when I take the key out so it's definitely working I will give it a clean. Cheers

 

[A noddy]

Still not fixed changed the glow plugs , coolant temp sensors , cleaned the maf , recirculation valve , asr ..spotless still the same symptoms up to temp 90 give it a bit of gas and it dies won't start again till it's cooled down. unplugged the crank sensor car won't start plug it back in it and it fires up so I'd say that's ok

Still have a cold radiator so could be an airlock after changing thermostat ..any ideas welcome I'm losing my mind with this thing ..it will happily sit at idle for hours cheers

 

[Jezza16v]

If you give it some revs without driving it does it still cut out?

 

[A noddy]

No, you could revving it all day ..it's cracking me up definitely needs to completely cool before it starts again ..I'm gonna take the thermostat out again check I have no air lock, thanks again

 

[Jezza16v]

So it only stops when you drive off? Very odd. Have you tried unplugging the 'injection fuel temperature sensor', it will give you a fault code but the ecu will revert to default values and the engine should still run. Also try unplugging the coolant and fuel temperature sensors at the same time. I think you are wasting your time with the thermostat/air lock theory.

 

[A noddy]

I'll give that a go I unplugged everything I could see the last time it cut out and nothing worked .scanned it and had about 6 errors due to unplugging everything , plugged back in and cleared the codes ..the radiator remains very cool even when temp at 90 cheers again

 

[Jezza16v]

The top hose should get pretty warm but the bottom hose is always much cooler unless you have been giving it some for a while. Diesels don't chuck out heat like petrol. Diesels are pretty hard to stop once they are running, no spark to switch off, you have to shut off the air or the fuel. The only thing that can shut off the air on this engine is the ASV. Let the engine cool to a point where you know it will start, disconnect the ASV and leave it disconnected, it will do no harm, (the engine will just shake a bit when you turn it off). Start the engine and warm it up like you do then go for a drive, clearly, be prepared for it to stop again, take a mate with you to push it.....If it stops again you definitely know that its not the ASV activating incorrectly and you can discount that. The things that would cut off the fuel would be (1) the electrical signal to the injectors is shut down by the ECU, normally due to failure of the crankshaft or camshaft sensor (2) a failure in the wiring to the injectors (3) a failure or lack of pressure from the fuel pump. None of these should be related to engine temperature but maybe heat/vibration combined might cause a temporary failure in a connector or the crankshaft or camshaft sensor. There may of course be a fault in the ECU or given the amount of electrical errors you have, some related to low voltage perhaps causing a temporary shut down of the ECU. The only other component showing an error which is dependent on speed is the ABS module, and of course the doors lock when you get above 5mph, but still not temperature dependent. Perhaps the temperature issue is a red herring as it gets hot when you leave it idling, it may be an electrical connection that gets hot and then breaks down, then when it cools it reconnects. Could even be an immobiliser fault? OK I give in..............

 

[A noddy]

Cheers again ..I actually went out and stripped out the auxillary heater tonight as that had thrown a fault just looking for any blackening or burst resistors etc..all looked ok nothing obvious so although it's not working it's not shorting the wiring or anything. I used Vcds to test the ASV and it cuts the car out but it starts again right away .

If I do manage to fix it or get it fixed I'll post it up, lots of probs on forums skoda v dub seat etc that sound similar one guys was fixed by changing the injectors ..blooming expensive so hopefully not that .

Cheers for all your help at least it's getting warmer for laying under the car!

Cheers

 

[Jezza16v]

I wish you the best of luck, the document on the link below might be helpful.
https://www.myarchive.us/richc/VW_TDI_with_PumpeDuse.pdf

 

[A noddy]

Cheers Jezza for your help. I will study the document you sent and take the appropriate action ..a small tap with a big hammer ha ha cheers John

 

[A noddy]

Fixed it !!! Thanks for all your help and input Jezza 16v +
All sensors I could get to were checked, removed and cleaned ASV, car would sit idling all day but would cut out when driving no noticeble faults on VCDS.
Yesterday decided to clean the MAP boost sensor , had to cut the screw off with a Dremel , I then decided just to change the Camshaft sensor .. voilà car fixed ...so far so good.

Looking back at the posts the camshaft sensor had been suggested but I assumed it would throw a code if it was badwhich it didn't.
I now know the TDI engine inside out ha ha

Thanks all who helped me get to this point!

 

[A noddy]

Cut out again ..garage time ha ha

 

[Jezza16v]

Bu**er! Crankshaft sensor intermittent fault maybe? Be sure to let us know when you have it sorted.

 

[A noddy]

Just an update, took the car to a garage who scanned it replaced the sensors I had done and still conked out. I agreed to have the crank sensor changed 90 quid from Audi, problem remains. I have taken the car back and £225 pounds lighter. They suggested my next step was to load the car on to a transporter 70quid and ship it to a diesel specialist ..for a bigger bill ..so I'm going to attack at myself again ..next job is the high pressure vacuum fuel pump ..strip n rebuild here's hoping ..cheers j

 

[Jezza16v]

Best of luck. Let us know if you get it sorted, so many threads die without a solution.

 

[A noddy]

Update ! I Purchased a tandem pump second hand fitted it car started straight away but unfortunately cut out again once hot. Both fuel lines from the filter to the engine were empty as I had put two inline filters in to see what was happening . Cheers

 

[Jezza16v]

Fuel lines empty!! Well, going right back to the start of you problem, when you put petrol in it you drained the tank and replaced the fuel filter........ Are you absolutely sure that you have not disturbed the fuel tank lift pump when you drained the tank? Maybe it is no longer working properly or at an adequate rate to run the car under load, try priming the fuel filter again to make sure it is working? Alternatively, if you have the replacement paper type fuel filter, and there seems to be a few variants out there, might you have somehow not got the top 'o' ring cluster in the wrong place so it is not sealing correctly to the four inlet/outlet pipes? Just a thought.........

 

[A noddy]

I think I'll take that pump out again and see what's happening ..its blooming annoying me now I was thinking of checking / replacing the injector seals but looks a bit complicated ..I'll try the pump first cheers ..

 

[Jezza16v]

With those fuel lines being empty the issue would definitely appear to be fuel starvation, the lift pump or a restriction in the filter canister/pipes. Nothing to do with the injectors.

 

[A noddy]

I think I've fixed it ...I traced both pipes from the filter back to the lift pump and put an online filter in what I thought from an internet pic was the return pipe ..this was the supply ..swapped them over and voila ..FIXED...the heating part as you pointed out was a red herring ...the fuel in the filter must have been enough for 20 mins of driving ...****** garage never even checked that ..they had it cut out twice ...I'm glad I used the eBay in line fuel filters to see what was going on ..THANKS AGAIN FOR ALL YOUR HELP !!! I' happy and ever so slightly annoyed I never did this earlier (I'm sure you suggested this) many thanks John

 

[Jezza16v]

Great news! I really hope you have it all sorted now.

 

[A noddy]

I hope so too, it will be like a new car, with all the sensors and cleaning ASV etc and a good run through with petrol ...cheers anyone need a tandem pump ha ha