ABS and ESR lights etc - Club Touareg Forums
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post #1 of 11 Old 03-30-2019 Thread Starter
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Smile ABS and ESR lights etc

I replaced rear rotors/pads on a 2004 T1 for a WOF (Govt. safety check). All went well but on start up I got an ABS and ASR (triangle with exclamation mark) lights. They went away the next day and went an got my my WOF (so passed the brake test OK). The next day they came back on together with a brake assist light.
I did a VCDS scan:

VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 12.12.0.0
Data version: 20130910


VIN: WVGZZZ7LZ5D030828 License Plate: SAT29/3
Mileage: 258150km-160406mi Repair Order:



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


Chassis Type: 7L (7L - VW Touareg (2003 > 11/2006))
Scan: 01 02 03 05 06 08 09 11 13 15 16 17 18 19 1C 22 29 32 34 36
37 39 3C 46 47 55 56 57 64 65 68 69 6C 6D 6E 75 76 77

VIN: WVGZZZ7LZ5D030828 Mileage: 258150km/160406miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: None
Part No SW: 022 997 034 C HW:
Component: MOTRONIC ME7.1.1G 0240
Coding: 0001133
Shop #: WSC 00090 824 68145
VCID: 173D2DDE252DA9A6459-517A

1 Fault Found:
17887 - Brake Boost Vacuum System
P1479 - 008 - Mechanical Failure
Readiness: 0010 1101

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 09D-927-750.lbl
Part No: 09D 927 750 BN
Component: AL 750 6A 0586
Coding: 0004136
Shop #: WSC 00090 824 07852
VCID: 7BF5116E39456DC6C11-517A

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 7L0-907-379-MK25.lbl
Part No: 7L0 907 379 G
Component: ESP ALLRAD MK25 0203
Coding: 0014594
Shop #: WSC 31414 000 00000
VCID: 3D71DF7667D1A3F6BF5-517A

2 Faults Found:
00778 - Steering Angle Sensor (G85)
000 - - - Intermittent
01276 - ABS Hydraulic Pump (V64)
012 - Electrical Fault in Circuit - Intermittent

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. Labels: 3D0-909-13x-05.lbl
Part No SW: 3D0 909 135 N HW: 5WK 470 21
Component: Kessy 6610
Revision: 66105312 Serial number: VWZ3Z0D1253565
Coding: 0000232
Shop #: WSC 31414 000 00000
VCID: 306FF642A0835E9E243-5198

Subsystem 1 - Part No: XXXXXXXXXXX
Component: ELV XXXX

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 7L6-907-040.clb
Part No: 7L6 907 040 H
Component: CLIMAtronic R/L X 3716
Coding: 0000020
Shop #: WSC 31414 000 00000
VCID: 3561C7565FE17BB6775-5198

1 Fault Found:
01592 - Air Quality Sensor (G23
010 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 7Lx-937-049-V1.clb
Part No: 7L6 937 049 K
Component: 2703
Coding: 0105724
Shop #: WSC 31414 000 00000
VCID: 4487AA92043BD23EF0B-5198

1 Fault Found:
01520 - Rain and Light Recognition Sensor (G397)
008 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 3D0-909-601.lbl
Part No: 3D0 909 601 E
Component: 0B Airbag 8.4E+ H10 0951
Coding: 0012354
Shop #: WSC 31414 000 00000
VCID: 25411716EF410B36C75-5198

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 7L6-953-549.lbl
Part No: 7L6 953 549 D
Component: Lenksäulenmodul 3301
Coding: 0000031
Shop #: WSC 31414 000 00000
VCID: 408FA6821023CE1ED43-5198

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 7L6-920-xxx-7LA.lbl
Part No: 7L6 920 880 K
Component: KOMBIINSTRUMENT RB8 2921
Coding: 0007121
Shop #: WSC 31414 000 00000
VCID: 3F8DA57E6DDDB1E6AD9-517A

1 Fault Found:
01304 - Radio
004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<>CAN 0101
Coding: 0000006
Shop #: WSC 31414 000 00000
VCID: F0EFB642E0039E9EE43-517A

1 Fault Found:
01304 - Radio
004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 22: AWD Labels: None
Part No: 0AD 927 755 BE
Component: TRANSFERCASE 0122
Shop #: WSC 00000 000 00000
VCID: 7F0DE57E2D5D71E6ED9-5198

No fault code found.

-------------------------------------------------------------------------------
Address 29: Left Light Labels: 3D0-909-157.lbl
Part No: 3D0 909 157
Component: EVG GDL+AutoLWR(l) 0001
Coding: 0000003
Shop #: WSC 31414 000 00000
VCID: E6C3D01AD2C7402E8EF-5198

No fault code found.

-------------------------------------------------------------------------------
Address 34: Level Control Labels: 7Lx-907-553-34.clb
Part No: 7L0 907 553 F
Component: LUFTFDR.-CDC- 3C3P1 3081
Coding: 0015521
Shop #: WSC 31414 000 00000
VCID: 3663C05A42E770AE7EF-5198

2 Faults Found:
00778 - Steering Angle Sensor (G85)
004 - No Signal/Communication - Intermittent
01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 39: Right Light Labels: 3D0-909-158.lbl
Part No: 3D0 909 158
Component: EVG GDL+AutoLWR(r) 0001
Coding: 0000003
Shop #: WSC 31414 000 00000
VCID: E7DDDD1ED5CD5926B59-517A

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 7L0-959-933.lbl
Part No: 7L0 959 933 E
Component: GR HSG 0200
Coding: 0000069
Shop #: WSC 31414 000 00000
VCID: 3E73D87A6AD7B8EEA6F-4B50

Subsystem 1 - Part No: 7L0 959 701 C
Component: Tuersteuergeraet FS 0201

Subsystem 2 - Part No: 7L0 959 702 C
Component: Tuersteuergeraet BF 0201

Subsystem 3 - Part No: 7L0 959 703
Component: Tuersteuergeraet HL 0201

Subsystem 4 - Part No: 7L0 959 704
Component: Tuersteuergeraet HR 0201

Subsystem 5 - Part No: 7L0 907 719
Component: Neigungssensor 0020

Subsystem 6 - Part No: 7L6 951 171
Component: A Innenraumsensor 0019

1 Fault Found:
00893 - Switch for Trunk Handle (E234)
007 - Short to Ground

-------------------------------------------------------------------------------
Address 68: Wiper Electr. Labels: None
Part No: 7L0 955 119 G
Component: Front Wiper 2416
Coding: 0000004
Shop #: WSC 31414 000 376832
VCID: 387FCE6248F386DE6C3-5198

No fault code found.

-------------------------------------------------------------------------------
Address 76: Park Assist Labels: 3D0-919-283.lbl
Part No: 7L0 919 283 F
Component: 0E Einparkhilfe 1107
Shop #: WSC 00000 000 00000
VCID: 3979CB6673F99FD693D-517A

No fault code found.

End ---------------------------------------------------------------------


I had read that low battery can cause some errors so replaced the battery as it was at least 5 years old and not under rated for the car. This scan was run after this so it didn't seem to make any difference. I also checked all fuses/fuselinks form the battery and all fuses on left and right fuse boxes. I checked the splices under the carpet on the LHS and it looked fine with no corrosion but remade the 3 splices. I also checked and cleaned the earth/ground for the abs module.
It seems that it is not just coincidence that it happened after the brake work. I also replaced the wear indicators for both sides. ABS wheel sensors were not touched and visually appear OK.
Any help would be greatly appreciated!

I also checked under the left
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post #2 of 11 Old 03-31-2019
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2004 does not have any electronics near the rear brakes. You have two wear sensors, but that is just a simple open/closed loop of wire. No way that should effect the electronics.

There is the abs sensors, but that should not do this. 2004 don't have the electronic parking brakes (thankfully) and the only other thing back there might be some wires if you have the air suspension. Nothing that should cause this.

Did you do any other work that day such as change brake fluid? Perhaps something happened under the hood? So, we need to think thru what else we touched that day to see if any of that could have had any effect.

If you had not checked the splices, I would say that this looks like that start of "loss of canbus" that comes when a canbus splice is going bad. There have been some people who have had the same symptoms when a mouse got into and chewed the wiring. I guess it could be some non-splice damage to the wiring.

I would reset all codes with VCDS and see what codes came straight back. If no codes, it is time to wait. If the exact same codes come back, the errors are probably real. If a random mix of codes come back, then it is wiring damage.

The only other thing you could throw into the mix would be a battery disconnect. Leave the cable off for a few hours so that the system can discharge. When you reconnect, you will get a steering error. Just drive straight backwards 50 feet, stop, and then straight forward 50 feet returning to your original point to fix that. The auto stop windows will need the button held down one full up and down cycle and then the auto function will work. Memory seats may need one full cycle for the auto function to work. Just run them all the way forward and all the way back if needed.

Short version: Basically you will be doing a lot of clear codes, waiting, and read codes.
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post #3 of 11 Old 03-31-2019
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Quote:
1 Fault Found:
17887 - Brake Boost Vacuum System
P1479 - 008 - Mechanical Failure
Readiness: 0010 1101
If this error persists, you need to fix the vacuum lines around the engine. A common problem on the T1 currently as the factory plastic lines are dying. Best way is to use a smoke machine to find the leak points, as you often can not see them.
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post #4 of 11 Old 03-31-2019 Thread Starter
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Firstly thanks for your reply! I should have mentioned that it is a 3.2V6 auto with air suspension and that I have cleared the codes multiple times and they immediately come back. The 17887 - Brake Boost Vacuum System
P1479 - 008 - Mechanical Failure has been around for awhile and yep it is the vac tubing that failed. I replaced most of it with silicone tubing and that fixed the lack of brake boost but I couldn't see under the LHS intake to figure out how that side goes together and had a go at "fixing" that but without a diagram it was largely a guess. Does anyone happen to have one?
I have tried disconnecting the battery for awhile, but I may try that overnight...but I know doing that can also create codes, but having a VCDS means I should be able to clear them OK.
The only thing I did that day was the rear brakes. I did push back the caliper pistons with a piece of wood, to fit the new pads, but clearly there are no leaks as the brakes are working fine. Brake fluid level is good so I do not think any air got in. I replaced the wear sensors with new ones, although the old ones had yet to wear through. I guess I could run the ABS bleed function in the VCDS...? I did think it may have been the battery being weak as it was not the correct battery and on test was only putting out about 150CCA not the 800CCA of the correct (now replaced) battery.
Do you think there could be a connection between the:
2 Faults Found:
00778 - Steering Angle Sensor (G85)
000 - - - Intermittent
01276 - ABS Hydraulic Pump (V64)
012 - Electrical Fault in Circuit - Intermittent and:
Address 34: Level Control Labels: 7Lx-907-553-34.clb
Part No: 7L0 907 553 F
Component: LUFTFDR.-CDC- 3C3P1 3081
Coding: 0015521
Shop #: WSC 31414 000 00000
VCID: 3663C05A42E770AE7EF-5198

2 Faults Found:
00778 - Steering Angle Sensor (G85)
004 - No Signal/Communication - Intermittent
01772 - Signal from Level Control Pressure Sensor (G291)
008 - Implausible Signal - Intermittent


I do sometimes get a level control fault on the MFD but it goes away when the car is shut down. I have rebuilt the compressor, but that does not seem to make any difference. The air suspension seems to work fine although sometimes at traffic lights the level will "settle" slightly. I don't know if that is normal?



It is a bit of mystery...but I will try the battery disconnect again in a couple of days when my wife is away and I can work on the car!
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post #5 of 11 Old 03-31-2019
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If the codes return immediately, imo a battery disconnect is not likely to help. I guess we could say nothing to lose by trying, but I will be shocked if it helps.

Factory radio? Some of the pinouts available for VW are incorrect and tell the installer to incorrectly mess with the canbus wires. This leads to endless problems.

At this point, my best guess is that we have a wiring issue or a lot of modules that failed at the exact same time. The first seems more likely. Are you 100% that the little canbus wire near the drivers door was correctly spliced? That one is so thin, that it often is hard to work with. I would not trust anyone's work on that wire until it was properly ohm'd out to verify continuity.

It does not happen often but it is possible for one canbus device to malfunction and destroy canbus communication on the system. The only way to troubleshoot for that is to unhook one of the modules that shows the error and scan the system. If no change, reconnect. They you disconnect the next device and scan the system. Repeat until you have tested every system that shows an error.

If you try that, start with the ABS module. It seems to be one of those that tends to fail more often. There are a couple of reports on here of people who have had them replaced and one person mentioned that you can mail off a VW abs controller to be fixed. That is all I know about it.

Every path that I see leads down a long and tedious process of troubleshooting the electrical system. Oh, what Fun and Joy.
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post #6 of 11 Old 03-31-2019 Thread Starter
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Mmm yes I tend to agree with you re battery disconnect as it didn't help before. I will start with disconnecting the ABS module and scanning as you suggest. Re the brown CANBUS wire - quite confident it was OK anyway. Zero signs of water ingress or corrosion, but I cut back both wires and soldered them together. I guess it is possible that it is broken somewhere else but I would expect more error codes if it was. I can send the ABS unit to Australia to be tested/repaired but that is definitely a last resort. I replaced the factory radio 5 years ago when I got the car and have not had any errors/problems with that.
Thanks again and I will post if I solve it!
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post #7 of 11 Old 03-31-2019 Thread Starter
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The only other thing is I have a non factory reversing camera that is now working intermittently...so I will disconnect the wiring for that in case it now screwing with the CANBUS.
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post #8 of 11 Old 03-31-2019
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It is not the radio being wired wrong if it has already been in there for 5 trouble free years!

I am going to give you this link to look at. The main reason, well, read the quote below and you will see why.

ecutesting.com/product-catalogue/volkswagen/touareg/abs-pump-ecumodule-combined/amc402634/

Quote:
Part Numbers: VM no: 7L0614111H / 7L0907379 / 7L0907379G OEM no: 10020402634 / 10.0204-0263.4 / 10092503313 / 10.0925-0331.3 / 10.0204-02623.4 / 100204026234 / 00008654D1

Vehicle Details: Make Volkswagen
Model TOUAREG
Engine Size:2.5 - 6.0
Specification TDI PD
Year2003 - 2007

Common Faults: There is a common fault with these ABS pump & ECU units for the Volkswagen Touareg 2.5 failing and causing the abs light to come on and various fault codes for wheel speed sensors etc
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post #9 of 11 Old 03-31-2019 Thread Starter
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Thanks I may end up sending it there, or the people in Australia...if nothing else works!
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post #10 of 11 Old 03-31-2019
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Contact one or both of them. They might be able to look at your VCDS scan and say if it "appears" a be a typical abs failure scan. They probably have seen several by this point.

If it is the abs controller, then the faults in the other modules should disappear just by unhooking the abs controller. No need to unhook everything looking for the lost needle. Just unhook the abs controller, scan, clear codes, scan, rehook abs, scan.

Be sure you save each scan. We should get a pretty good picture just by comparing the scans.
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