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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Mon Jun 02, 2025 12:53 pm Post subject: 03 EV finally threw a CEL Code |
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Saturday afternoon on the way home from the NW Bug Run. My EV threw a
P0203 CEL Code. I know what it means. Electrical fault for the #3 fuel injector.
Unfortunately, when it coded, I was on a two lane mountain rod and the engine died in the middle of a blind hair pin turn.
The stalled van was right in the middle of the roadway and it took myself and couple very helpful younger fellas to push the van off the roadway so traffic could pass by.
I managed to get the van started and up the mountain, then it died again.
I got it started, and made it about another two miles before it died yet again. Thankfully there was a road I could turn onto and scan the ECU to see what was up.
It showed the P0203 code and there was another that I didn't see before I cleared the code.
After clearing the codes, I was able to drive the remaining 14 miles home without any codes being thrown or the engine dying while completing my home bound trip.
Rather than throwing parts at the engine. I'd like to buy a KKL 409.1 USB adapter cable and download VCDS lite to analyze what is causing the van to die.
The issue I'm encountering is, the KKL 409.1 cables that I'm finding will not communicate with Windows 10. They all appear to work with older versions of windows that are no longer supported by MS.
I read a blog entry yesterday afternoon and the admin stated that the KKL 409.1 cable was just a dumb cable and should work with any version of windows.
Is that a true statement?
The engine dying is an intermittent issue that I have been experiencing over the last month.
I need this EV to be reliable transportation.
Currently it is not so.  _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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xEVC Samba Member

Joined: March 23, 2017 Posts: 129 Location: California
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Posted: Mon Jun 02, 2025 4:10 pm Post subject: Re: 03 EV finally threw a CEL Code |
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I messed around with el-cheapo USB cables and the lite (free) version of VCDS for a few years, and eventually spent the $ and got the real version. Wish I had done that earlier. The VCDS model which supports three (3) VINs (three different Eurovans, which is 2 more than I have) is $200, and I'm sure I spent way more than that of my time and angst with the cheap USB dongles.
The real VCDS hardware also runs faster, and seems more bug free - one thing you don't want to be doing when debugging your Eurovan is to actually be debugging the hardware dongle! _________________ 2000 Eurovan Camper (Winnebago)
Upgraded with 16" wheels |
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kourt Samba Member

Joined: August 13, 2013 Posts: 2305 Location: Austin, TX
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Posted: Mon Jun 02, 2025 4:56 pm Post subject: Re: 03 EV finally threw a CEL Code |
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I second this post. Pay for the real deal. Cry less.
I know people throw shade on Ross Tech for charging for their software. It's worth it.
kourt |
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HeyCrutch Samba Member
Joined: August 12, 2022 Posts: 414 Location: Asheville, North Carolina
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Posted: Mon Jun 02, 2025 5:03 pm Post subject: Re: 03 EV finally threw a CEL Code |
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Been waiting to ask this question ...
As a Mac-only user for probably 15 years now. Given that Ross-Tec's VCDS software only runs on Windows ... does anyone have a good recommendation for a bare bones windows computer that would be sufficient to run VCDS? It's almost embarrassing that I actually have 3 eurovan and don't yet have the software. Baby steps.
I know this isn't a computer forum, but maybe there are other people out there who were in my boat and had the same desire ... just a machine that will run it and do nothing else ... I have Mac's for everything else.
As usual, thanks very much!! _________________ -2003 EV MV Wk - Forest - 51k
-2002 EV Camper - Ghost - 82k
-2003 EV GLS - Fluffhead - 176k
-1997 EVC - 12vVR6 (SOLD 5/2025) |
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xEVC Samba Member

Joined: March 23, 2017 Posts: 129 Location: California
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Posted: Mon Jun 02, 2025 5:28 pm Post subject: Re: 03 EV finally threw a CEL Code |
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Good question!
I use the most recent 11" MacBook air (which was 2015) on which I installed Windows 10 under BootCamp a while back and then VCDS.
It works great, and the 11" MBA is tiny and takes up little space and is worth like $50 so if it got stolen, who cares.
I have wondered about other ideas (VMs on my more modern MacBook, BlueTooth solutions from an iPad, etc.).
But philosophically, if life is good, I should NOT be running VCDS.
If I am running it, it suggests my life is abnormal, and I will dig out the MBA11.
That's my solution for now. _________________ 2000 Eurovan Camper (Winnebago)
Upgraded with 16" wheels |
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kourt Samba Member

Joined: August 13, 2013 Posts: 2305 Location: Austin, TX
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Posted: Mon Jun 02, 2025 7:34 pm Post subject: Re: 03 EV finally threw a CEL Code |
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I use an old 11" MacBook Air (Early 2015), Intel based laptop, running the highest version of macOS it will tolerate. This particular laptop also happens to be the smallest laptop Apple ever made.
On that laptop I run VirtualBox, a free emulation framework from Oracle. In essence, you run Windows inside of macOS, and can shift between the Windows virtual machine and macOS freely while working, thus allowing you to use the internet, take snapshots of your virtual machine, and restore them if you break Windows.
You still need to source your own copy of Windows to install on your VirtualBox virtual machine. I think I'm running Windows 10.
On that copy of Windows I run VCDS (for VW products) and VIDA (for Volvo products). This old laptop is used exclusively for car repair software. I also keep a full copy of VW Erwin on it.
This has been a good setup for me. Old Apple hardware holds its value and performs better for much longer than other brands, in my experience.
VirtualBox is available for Apple Silicon laptops, but it simply does not want to run Windows, so don't waste your time building this setup on a newer Silicon laptop.
There is a pricier version of VCDS that has its own inbuilt web server, which means you access it via a self-created local wireless network, and it doesn't care what platform you're on, as the interfaces are all browser based. Costs more, but you can use it with any tablet or phone or laptop. That web based access is not fully featured, but I can see how it could save you in a difficult situation on the road.
kourt |
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psbales Samba Member
Joined: November 28, 2020 Posts: 8 Location: Augusta, GA
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Posted: Mon Jun 02, 2025 7:46 pm Post subject: Re: 03 EV finally threw a CEL Code |
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@HeyCrutch - Any Intel-based laptop with at least a Core i3 would do. You can even save a few bucks if you pick up one at Best Buy open-box. It might have a few scratches, but it'll be fine for a knock-around shop laptop.
Make sure it has a USB-A port for any cables.
Stay away from any Celeron processors - they're crap at anything in my experience.
There's also deals to be had with AMD CPUs, but I know less about them. |
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mikemtnbike Samba Member
Joined: March 26, 2015 Posts: 2926 Location: North Carolina
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Posted: Tue Jun 03, 2025 6:00 am Post subject: Re: 03 EV finally threw a CEL Code |
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kourt wrote: |
I second this post. Pay for the real deal. Cry less.
I know people throw shade on Ross Tech for charging for their software. It's worth it.
kourt |
I'd much rather pay once than pay a subscription fee. Thanks ross-tech!
Crutch, you will also find VCDS to be fun/useful for your alltrack. Just getting rid of the "it might be icy" audible alarm on my GTI that really ticked me off was worth the price of VCDS. I also turned off the fake engine/exhaust noise that VW was piping in to my cabin. _________________ 1991 Vanagon GL 2.1 AT Westfauxlia. "Frankie" Totaled https://www.thesamba.com/vw/forum/viewtopic.php?t=764510&highlight=carnage
1995 Eurovan Camper "Marzivan"
2020 GTI SE manual |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Tue Jun 03, 2025 2:13 pm Post subject: Re: 03 EV finally threw a CEL Code |
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Just ordered the Ross Tech VCDS.
Now we'll see how long it takes to make through the USPS system to get here.
Then, I'll have a bunch of questions on operating the VCDS scanner.  _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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jjvincent Samba Member
Joined: January 11, 2016 Posts: 1421 Location: Bethlehem, PA
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Posted: Tue Jun 03, 2025 3:24 pm Post subject: Re: 03 EV finally threw a CEL Code |
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A few options.
1. Buy the VCDS and just use the App that works on an iPhone. Apple makes the iPhone so for people that are hell bent on just using Apple products, there's your option.
2. But a used laptop (i.e. Dell) that runs Windows for like $100. Then keep it in your EV and use it for just scanning your EV. I still have an old laptop from 2010 and guess what, it still runs my VCDS. If a 15 year old laptop or my current iPhone can run my VCDS, I think you might be in luck. |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Mon Jun 09, 2025 12:21 pm Post subject: Re: 03 EV finally threw a CEL Code |
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67rustavenger wrote: |
Just ordered the Ross Tech VCDS.
Now we'll see how long it takes to make through the USPS system to get here.
Then, I'll have a bunch of questions on operating the VCDS scanner.  |
Ok, so I have my new ross-tech VCDS ODB dongle in hand. I have downloaded and installed the software.
I'm at the point of "test." Do I run the initial test with the EV engine running or not?
As for now, the rest of the software boxes to open look fairly intuitive. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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kourt Samba Member

Joined: August 13, 2013 Posts: 2305 Location: Austin, TX
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Posted: Mon Jun 09, 2025 12:50 pm Post subject: Re: 03 EV finally threw a CEL Code |
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Link
I usually Auto Scan with key in Position II. Select your chassis in the software.
Kourt |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Mon Jun 09, 2025 1:04 pm Post subject: Re: 03 EV finally threw a CEL Code |
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I kinda found the answer in the ross-tech FAQ's.
I'll watch that video and I'm sure it will help things along.
Thank you kourt. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Tue Jun 10, 2025 10:24 am Post subject: Re: 03 EV finally threw a CEL Code |
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Ok, so I managed to scan the van via the VCDS.
Two codes were found,
P1516 (N156) intake manifold valve open circuit.
On an 03 EV 2.8 24v, where is this intake valve located?
I looked in the engine compartment and cannot see where it's located.
The other is,
P1848 Intermittent ABS Brakes, this one seems fairly common based on the google searches I have been doing this morning.
I'll clear the DTC and see if the ABS issue returns. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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kourt Samba Member

Joined: August 13, 2013 Posts: 2305 Location: Austin, TX
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Posted: Tue Jun 10, 2025 2:53 pm Post subject: Re: 03 EV finally threw a CEL Code |
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I am fairly certain that on the 2001-2003 VR6 engines, the intake manifold valve is controlled by the vacuum driven system on the passenger side of the intake, as shown below, with red markups around it. [photo borrowed from this thread]
The vacuum chamber and piston operate a set of butterfly valves within the intake manifold. First check the vacuum lines, and then check the wiring serving that device. This is a common vacuum line failure area.
kourt
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Tue Jun 10, 2025 3:40 pm Post subject: Re: 03 EV finally threw a CEL Code |
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Thank you once again kourt.
I had spotted that valve when I was checking the air cleaner last month.
I wasn't sure what I was looking for in this instance.
I'll pull the MAF piping and see if the vacuum lines are in good nick.
Then check the wiring attached to the valve. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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kourt Samba Member

Joined: August 13, 2013 Posts: 2305 Location: Austin, TX
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Posted: Tue Jun 10, 2025 3:46 pm Post subject: Re: 03 EV finally threw a CEL Code |
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What I would do here is replace the vacuum lines in that area, and then open all wiring connectors and treat them with DeoxIT, then reconnect them.
kourt |
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SambaBurnsRed Samba Member
Joined: February 07, 2025 Posts: 58 Location: object:1698
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Posted: Wed Jun 11, 2025 11:12 am Post subject: Re: 03 EV finally threw a CEL Code |
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When was the last time the Crank sensor was replaced?
There's not a lot that can kill the motor outright, intermittently, other than that sensor or power to the engine ECU |
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67rustavenger Samba Member

Joined: February 24, 2015 Posts: 10970 Location: Oregon
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Posted: Wed Jun 11, 2025 11:19 am Post subject: Re: 03 EV finally threw a CEL Code |
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Well, it took all of 50 minutes to r&r the intake tube between the MAF and the TB.
Once I got a clear view of the problem, it was apparent what the "open circuit" issue was. The wire connector just below the green circle in the above pic was completely disconnected from the valve
I cleaned up the connector and reconnected it to the intake valve.
While I had access to that area. I checked the vacuum lines (indicated by the red arrow) in the pic kourt posted. Sure enough they were cracked and likely leaking.
Went to the FLAPs and bought a 2' length of vacuum hose and replaced all the cracked hoses.
After, I started the van and it didn't throw any codes, yet. I'm gonna drive it a few miles and rescan with VCDS when I get back home.
I'll report back if the issue didn't clear up.
The above really doesn't clear up the intermittent engine stall while driving, I think. I guess I'll find out soon enough. _________________ I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!
There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!
2003 Astrovan? GFYS again, Xevin!  |
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Abscate  Samba Member
Joined: October 05, 2014 Posts: 23743 Location: NYC/Upstate/ROW
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Posted: Thu Jun 19, 2025 5:30 am Post subject: Re: 03 EV finally threw a CEL Code |
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jjvincent wrote: |
A few options.
1. Buy the VCDS and just use the App that works on an iPhone. Apple makes the iPhone so for people that are hell bent on just using Apple products, there's your option.
2. But a used laptop (i.e. Dell) that runs Windows for like $100. Then keep it in your EV and use it for just scanning your EV. I still have an old laptop from 2010 and guess what, it still runs my VCDS. If a 15 year old laptop or my current iPhone can run my VCDS, I think you might be in luck. |
Reading through this you still need a Windows PC to setup , even if you will use a smart phone interface. Itβs a $500 product with up to ten VINS , so that works for me. Iβll easily recover that in shop fees to widows and orphans. _________________ πΊπΈ πΊπΈ πΊπΈ πΊπΈ πΊπΈ πΊπΈ πΊπΈ π π π |
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