Sensor gremlins - Help needed

Bryan2411

Bryan2411

2014 SE
VIP Member
Messages
144
Location
Bedford, UK
Vehicle
T5 SE 180 4Motion
Hello all,
About 2 years ago our Cali (T5.1 2014 180) developed issues while on holiday. A range of error codes came up which couldn’t be dealt with so sadly she was recovered back to the UK. This resulted in a new ‘main’ CPU supplied from VW at not a small cost which was fitted by a garage I’ve used for years who's service is unquestionable.
All was well until this week whenI had a warning of an error in the Stop/Start system, which cleared on restarting the vehicle.
My better half was then taking the Cali to the garage for an MOT and service, when the van went into limp mode. Having spoken briefly to the garage, they’re saying that various fault codes are coming up but if cleared, the faults are intermittent with mechanics driving the vehicle with no problem but after a second test drive returning to limp mode again.
I’m speaking with the garage later today to confirm the nature of the fault codes et cetera, the garage say it could be something as simple as a loose connection somewhere in the system, or at worse a wider issue they don’t know about.
I was wondering does anyone out there know of a T5/Cali electrical specialist who can hunt down the cause of this problem? We are based in Bedfordshire, but are willing to speak to anyone anywhere in the first instance. Must ask, could these issues be related to EGR issues (We have a Type A cooler)? Though when running there is not excessive oil use etc? I have vague memories of browsing this forum someone mentioning a wonder auto electrician but the search function is down again.
We are due to go to Croatia in 6 weeks would really like to get this bottomed out and have our confidence returned.
Many thanks
 
Hello all,
About 2 years ago our Cali (T5.1 2014 180) developed issues while on holiday. A range of error codes came up which couldn’t be dealt with so sadly she was recovered back to the UK. This resulted in a new ‘main’ CPU supplied from VW at not a small cost which was fitted by a garage I’ve used for years who's service is unquestionable.
All was well until this week whenI had a warning of an error in the Stop/Start system, which cleared on restarting the vehicle.
My better half was then taking the Cali to the garage for an MOT and service, when the van went into limp mode. Having spoken briefly to the garage, they’re saying that various fault codes are coming up but if cleared, the faults are intermittent with mechanics driving the vehicle with no problem but after a second test drive returning to limp mode again.
I’m speaking with the garage later today to confirm the nature of the fault codes et cetera, the garage say it could be something as simple as a loose connection somewhere in the system, or at worse a wider issue they don’t know about.
I was wondering does anyone out there know of a T5/Cali electrical specialist who can hunt down the cause of this problem? We are based in Bedfordshire, but are willing to speak to anyone anywhere in the first instance. Must ask, could these issues be related to EGR issues (We have a Type A cooler)? Though when running there is not excessive oil use etc? I have vague memories of browsing this forum someone mentioning a wonder auto electrician but the search function is down again.
We are due to go to Croatia in 6 weeks would really like to get this bottomed out and have our confidence returned.
Many thanks
Sorry to hear of your problems.
I think you/we really need some more information before jumping to conclusions that it is just a faulty sensor etc:.

How many miles has the vehicle done?
What type of trips - short/long , mixture?
Is it used all year round or stored over winter?

Actual Diagnostic codes?

Any evidence of water leaks in drivers footwell or by/under front seats?
 
I agree with Welshgas. I have a code reader and then actually Google the fault codes. There is always then something on other VW van forums that gives me an idea. Also describing symptoms in more detail might get the mechanics on here helping.

I mentioned https://maps.app.goo.gl/SfygPtyapBHBqhgAA?g_st=ic on the forum which I used to fix my broken electric door. They were great but can’t guarantee they would help. Definitely very good guy called Rob.

With search function broken, if you Google Vw California and then what you want to find, Google usually takes you to the right place on the forum.
 
have you changed or had changed any abs sensors lately ? i had one fail on my bmw, fitted a new one and it threw up every possible error code you could imagine. the new one was cheap/wrong one from ebay
 
Hi all,
Many thanks for the replies, I appreciate it was short on detail, having minimal information myself. I was just massively fearful of the same cycle of problem solving we went through the last time.
Anyhow, I now have the codes from the garage and they seem to generally centre around the EGR system.

01-Engine Management
P040100 Exhaust Gas Recirculation Flow Insufficient Detected
P040600 Exhaust Gas Recirculat. Sensor A Circuit High
P046C00 Exhaust Gas Recirculation Sensor "A" Circuit Range, Performance

08-Aircon
B108E71 Servo Motor For Rear Temperature Flap, Actuator Jammed

09-Central Electronics
03304 Response Closing Status of Right Rear Door Not A Plausible Signal - Intermittent

OBDII Codes ($03)
Р0406 EGR Sensor "A" Circuit High


They have searched their systems found suggested actions with regard to the fault codes of:
Checking particulate filter, which may require cleaning or replacement
EGR Valve replacement

To do this stuff they suggest a lot of work needs to be done to disassemble the front of the van, so while doing so I was thinking of just replacing the existing type A cooler to a type D cooler for piece of mind.

The garage are aware I’ll be posting here and want me to be happy before they start undertaking significant work. They’re good like that.

Anyone got any other suggestions or views?

Thanks again
 
Hi all,
Many thanks for the replies, I appreciate it was short on detail, having minimal information myself. I was just massively fearful of the same cycle of problem solving we went through the last time.
Anyhow, I now have the codes from the garage and they seem to generally centre around the EGR system.

01-Engine Management
P040100 Exhaust Gas Recirculation Flow Insufficient Detected
P040600 Exhaust Gas Recirculat. Sensor A Circuit High
P046C00 Exhaust Gas Recirculation Sensor "A" Circuit Range, Performance

08-Aircon
B108E71 Servo Motor For Rear Temperature Flap, Actuator Jammed

09-Central Electronics
03304 Response Closing Status of Right Rear Door Not A Plausible Signal - Intermittent

OBDII Codes ($03)
Р0406 EGR Sensor "A" Circuit High


They have searched their systems found suggested actions with regard to the fault codes of:
Checking particulate filter, which may require cleaning or replacement
EGR Valve replacement

To do this stuff they suggest a lot of work needs to be done to disassemble the front of the van, so while doing so I was thinking of just replacing the existing type A cooler to a type D cooler for piece of mind.

The garage are aware I’ll be posting here and want me to be happy before they start undertaking significant work. They’re good like that.

Anyone got any other suggestions or views?

Thanks again
I would do exactly that. Will be minimal extra cost once the front of the bus is off. Do you drive it hard up the rev range allowing the engine to work properly? I always allow mine to rev high and let it open up once hot, wether this prevents any clogging remains to be seen but no issues in 6 years so far
 
Hi all,
Many thanks for the replies, I appreciate it was short on detail, having minimal information myself. I was just massively fearful of the same cycle of problem solving we went through the last time.
Anyhow, I now have the codes from the garage and they seem to generally centre around the EGR system.

01-Engine Management
P040100 Exhaust Gas Recirculation Flow Insufficient Detected
P040600 Exhaust Gas Recirculat. Sensor A Circuit High
P046C00 Exhaust Gas Recirculation Sensor "A" Circuit Range, Performance

08-Aircon
B108E71 Servo Motor For Rear Temperature Flap, Actuator Jammed

09-Central Electronics
03304 Response Closing Status of Right Rear Door Not A Plausible Signal - Intermittent

OBDII Codes ($03)
Р0406 EGR Sensor "A" Circuit High


They have searched their systems found suggested actions with regard to the fault codes of:
Checking particulate filter, which may require cleaning or replacement
EGR Valve replacement

To do this stuff they suggest a lot of work needs to be done to disassemble the front of the van, so while doing so I was thinking of just replacing the existing type A cooler to a type D cooler for piece of mind.

The garage are aware I’ll be posting here and want me to be happy before they start undertaking significant work. They’re good like that.

Anyone got any other suggestions or views?

Thanks again
Basically for the 180 the front has to come off to access the EGR valve.
How many miles have you done?
 
65000 miles.

She isn’t a daily runner, but I do make a point joining roads on slips etc under power once warmed up.

I've not noticed excessive oil consumption to date.
 
I had a faulty EGR at 45000km when the van was 3,5 years old.
Luckily I have the 140hp engine, so the EGR sits on top of the engine. I changed the EGR myself on a campsite in the Dordogne in France.
Has been flawless since then.
 
I think the smoking gun for the limp mode is the insufficient flow in the EGR cooler. These get sooted up.
The EGR cooler is on the right-hand end of the engine and, as mentioned, is normally accessed with the van's front end removed in service mode. These can be cleaned out, but you'll be cleaning it again. It may be better just to have it replaced. Also, check that the rear EGR pipe is not cracked, as this may also be giving a false flow reading. You can check this by holding a mirror or taking a photo down the back of the engine and finding the small metal concertina hose that goes from the turbo outlet to the EGR valve. There will be soot on it if it splits.
 
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