[g500xl]

Yet another KESSY success. I put the two new MOSFETs on the board last week and nothing happend, so I pulled it and checked over all the resistors, cleaned it up and remounted the MOSFETs and it's now working great.

There seems to be a little bit of erratic behavior but I haven't check the codes yet.

Take your time and it seems to be a great fix. Thanks guys!!!

BTW, though my resistors were not bad (I did have to re-solder one of the small one's of the source side) they were not of the same size that was mentioned in one of the earlier posts, there was actually quite a variance in the sizes on the board, so check it before you replace it.

Thanks again.

 

[g500xl]

I cleared the codes yesterday afternoon and it appears to have helped a little. Looks like I'm now facing a bad (or disconnected) door handle(s) as one does not work and another unlocks if you walk too close to it. None of them seem to unlock with a touch but a double pull on the handle works, so maybe all the handles are partially bad.

 

[g500xl]

I'm going to say it's most likely a bad connection on one of the new MOSFETS or resistor just off of a leg. I'd recheck the solder points.

 

[g500xl]

Visually you'll probably never be able to tell. I was able to get a resistance with an Ohm meter through all the resistors on my board without desoldering them and just compared them with similar resistors on the board.

 

[g500xl]

Tom that's some good troubleshooting. Can you provide some specific info about the VAGCOM addresses and door handle troubleshooting. I'm especially interested in the door handle as I have not taken mine apart yet but will need to replace one or two soon.

I think your right in that the module senses when there is a problem, the new Mosfets give the system power so you can troubleshoot further. From what I understand, when those are out codes will not throw to the specific door handles so it must be fixed first..
Hope it works out for you.

 

[g500xl]

I'm not aware of a clicking noise. When I did not have a good connection on the MOSFET it acted just as it did before, I guess I never checked signals of the buttons I just know they didn't work. Do your button's work to lock it? If not I'd still lean toward a bad MOSFET or bad solder.

You might try leaving the cover off the module and plugging it in, I believe mine hung down enough that you might be able to pinpoint what is making noise.

Generally a clicking noise would be a relay of some sort so I'm thinking that it is probably not from the KESSY module but another module. Here's a thought, Do you have the auto door lock option set? I think it's in the system display when your stopped. If so this may be the vehicle attempting to lock the doors and a short in a wire takes out one or more MOSFETs. Kind of a long shot of a thought but if it's the case I'd hate to put another one it there that gets destroyed the next time you drive it.

 

[g500xl]

EEPROM; Whoaa, how did you get into that?

Sorry don't have an answer for you.

 

[g500xl]

but all four door handles shouldnt be bad should they. Any way I was wondering if anybody new how to test the antennas and handles to see if faulty other than vag-com?

Aside from Vag-Com or just using the handles I know of no other way. Either of those is easier than pulling a handle to check anyway. If you don't have a Vag-Com and want to do any troubleshooting, repairs, or keep your Touareg for very long I would strongly recommend purchasing one. I bought mine five years ago for my A4 and wondered why I didn't buy it sooner, best purchase for the Audi and VW by far.

As for all four being bad, I wouldn't think it's out of the question. There were lots of bad stories about the system and handles needing replaced but I would also generally agree with you, all four? All four also still points to the KESSY module itself having a bad component. If you get access to a Vag-Com (or buy one) try clearing the codes and see what works and which handle causes it not to work. It could be one handle causing a short but the problem there is it may burn out the MOSFET(s) each time that handle shorts out, (I hope not for your sanity).

Let me ask one more question. After your KESSY rebuild was there any change or did stuff still not work? I had to rebuild mine twice to get good solder joints all the way around, (guess I needed some practice).

Hope that gives you some help though I'm not sure I've given you anything new.

 

[g500xl]

The whole thing is soldered to the board. The upper tab extends down the back side and acts as the grounding point. You'll have to put the iron on the upper tab and heat it up till it comes off, it might take a while before it does, just be sure you have a good clean and tinned tip so that the heat is transfered efficiently. Also use a pair of tweezers or small needle nose pliers to maintain pressure on it so when it's ready you don't miss it.

 

[g500xl]

jcmuscarello,

Battery draw and buttons not working sounds like bad mosfetts.

If the remote in your pocket allows you to unlock the door by pulling the handle then the antennas are fine (From what I understand the antennas are located in each handle).

 

[g500xl]

I kept seeing everyone referring to the antennas being in the bumpers .

The antennas in the bumpers I believe are for the remote signal to lock/unlock the doors with the push of the button (or the panic button). The antennas in each door/door handle are a proxy antenna of sorts that enable the lock/unlock using the door handle when the key is within range of that door.

For example, if I walk up to the touareg with the key in my pocket on the drivers side and my wife walks up on the passenger side (or a bad guy depending on how you look at it) I will be able to unlock my door but the passenger side will not.

Oh, and it only unlocks with me pushing the button on the remote (Fob). The handle buttons or double pulling the handle doesn't work.

This confirms that you have a kessy problem (again probably MOSFETs and/or resistors on the board). While a kessy module replacement will also fix the problem it is much, much cheaper to have new components replaced on the board (which is what this thread is all about).

 

[g500xl]

I am in the process of sorting out the exact same issue with my dealer. Only one of my handles does not work, the other three work as expected.

So far I have replaced the Kessy unit at the dealer ($1000) total. The problem persisted but the dealer thought it was the KESSY programming. I was told the battery draw test was only 40mw.

Sounds like it is a bad antenna in the door handle. It could be a bad button and sensor also but more than likely a bad antenna. I don't recall anyone that has been able to repair a handle yet and I have not had mine apart to see what's in there. I've got one handle that's intermittent but it's a back door so I just try not to use it much, or open another door first and have my convenience setting set to unlock all doors upon the unlock signal.

You don't have the year of your touareg listed but there was an updated set of handles at some point in time that required a new KESSY module, I'm guessing you have a new style since they didn't replace all your handles when replacing the KESSY.

I think a person (or shop) can monitor the button push on the handle, the sensing of the hand in the handle, and whether the KESSY senses the key at the door (testing the antenna in the handle) using a VAG-COM. I'm sorry to say, but the shop you had replace the KESSY should have done this before paying out the big bucks to replace it.

 

[g500xl]

eyelise,

I tried getting you a copy of the handle disassemble but just didn't get a good copy last night. It pretty much looks like you'd have to take off the door panel to unplug the wiring harness. That might not be a bad idea since I am suspicious that a bad handle (or short) causes the MOSFETs (or the associated diodes) in the KESSY module to go bad which which causes the battery drain. I hate for you to mess up another module with the handle that doesn't work but this is only speculation.

 

[g500xl]

This is the same part number as the one West Florida Components had, just a little more expensive (currently $2.11 each) unless you buy in bulk. Digi-Key, with over 2500 in stock should be good to go for a few Kessy Modules.

IRFZ24NS

 

[g500xl]

Imanikrystelle,

Create a new thread in the "general maintenace & repair" forum. You'll get a much better response there as more people will read it.

 

[g500xl]

Thanks joeames,

I think might be some of my problems now as some functions are intermittent but I just didn't want to tear into a door panel without some reason to.