TheSamba.com :: View topic - 1Z Fault Codes new Transporter Conversion

Sun Sep 21, 2014 9:07 pm

Hi Folks--I have 1K on a 96 1Z in my 84 Euro Diesel Transporter. LOVE it! Holy shit, never thought I'd be able to get a speeding ticket in my van, but now it's a distinct possibility. I did a full rebuild on the 1Z, upgraded my ring and pinion, and she's a beaut. Anyway, the rig runs really well once it is warmed up, but she starts hard if I haven't run her for a while, and smokes quite a bit on start up. Also, the first time I hit the accelerator, she won't go, and goes to what I believe is limp mode. The next time I hit the accelerator she goes, spews a bunch of smoke, and then hauls ass and doesn't smoke any more withing 30 seconds. I've pasted the fault codes I'm getting below--any ideas on how to improve the starting and reduce the smoking? Also, what is the work around for eliminating the fault codes like the Washer Solution Metering Pump (which no longer exists in the Transporter) ? Do I need to add resistors or something? Or can I disable them through the computer? Is it likely I need to replace the fuel temp sensor? Thank you for your time and expertise--I really appreciate it.

7 Faults Found:
00309 - Washer Solution Metering Pump (V135)
31-00 - Open or Short to Ground
00310 - CAT Temperature Sensor 1 (G20)
30-10 - Open or Short to Plus - Intermittent
00750 - Warning Lamp
31-10 - Open or Short to Ground - Intermittent
00539 - Fuel Temperature Sensor (G81)
30-00 - Open or Short to Plus
00625 - Vehicle Speed Signal
27-10 - Implausible Signal - Intermittent
00522 - Engine Coolant Temperature Sensor (G62)
30-10 - Open or Short to Plus - Intermittent
65535 - Internal Control Module Memory Error
37-10 - Faulty - Intermittent

Sun Sep 21, 2014 10:20 pm

I'm just learning about the 1Z/AHU issues (I'm going to be doing my own AHU swap soon), so I'll do some research on your issues.

I found only a couple posts relating to the V135. Honestly I had never heard about it before and definitely isn't in my 1Z wiring diagram.

I hadn't seen the G20 sensor in my wiring diagram, but google search revealed this: http://forums.tdiclub.com/showthread.php?t=81167

Do you have a check engine light? The ECU will see if the bulb is burned out and give you a fault code for it. I think that is what the warning light fault is for.

The G81 is in the fuel pump itself. According to my diagram it is fed with a black/yellow (pin 7 at pump) wire and grounded with a brown/blue (pin 4 at pump). With the key on check power to pin 7 and you can check ground anytime at pin 4.

The VSS fault will occur if you don't have a speed sensor. I used the factory three wire sensor in back of the speedometer. It works great.

For the CTS (G62), you can check resistance based on the chart in the Bentley manual. My wiring diagram calls it a G27 but I know the later model ECUs call it a G62. Since it's named different, I'm not sure the wiring would be the same. But my diagram says it shares a common ground with a bunch of stuff (including the fuel temp sensor) and the other wire comes straight from the ECU.

And as for the 65535 fault, Ross Tech Wiki says this: http://wiki.ross-tech.com/wiki/index.php/65535. Quote: When found in certain older TDI Engine Control Modules (ECM) which have a vacuum line going to the ECU. Check/Repair the Vacuum Line before and inside the ECM. So double check that, especially inside the ECU. On later models, this usually means a bad ECU.

So check some of that stuff out and let me know what you find!

Wed Sep 24, 2014 9:17 pm

Thanks for the detailed reply hans j. I'll investigate.

Fri Sep 26, 2014 6:55 pm

What starter do you have? For me, what helped with hard starting was installing a TDI starter (Bosch SR0408X/409X) and using Westy Venture's adapter plate to make it fit (http://westyventures.com/parts.html). If you go this route make sure and get the proper connector for the starter wire if you want it to be reliable (you'd need http://idparts.com/catalog/product_info.php?products_id=4022, http://idparts.com/catalog/product_info.php?products_id=3707 and http://idparts.com/catalog/product_info.php?products_id=3820).

Although, I'd for sure figure out the codes you're getting first (except the V135 and G20, those are irrelevant for this conversion). The coolant temp sensor does tie into how long the glow plugs come on for, although I believe a disconnected sensor makes the glow plugs stay on a long time, which would only help starts.

David

Sat Sep 27, 2014 12:38 pm

Now that you mention it, my original diesel Transporter starter does seem a little sluggish. I still have the starter out of the donor 96 Passat and I'll put that in with the parts your recommend. Thank you!

Sat Sep 27, 2014 2:24 pm

Oh wait, the Westy Ventures adapter is only for waterboxer bellhousings. Yours would be a diesel bellhousing since it's originally a diesel from Europe, I believe? Sorry for the misinformation, although maybe just a new starter would be enough to get starting better. Not sure if there is a way to mate a TDI starter to a diesel bellhousing.

David

Sat Sep 27, 2014 4:48 pm

Is the ECU part # 028906021BK