2002 Turbo S won't start(crank) - fault finding suggestions?

[StephanT]

hi,

This morning we got in the car, drove 2 blocks, stopped at a stop sign, and it did not want to change into first (it's a 6spd manual of course), and then died... so I cycled the ignition, tried to start, but nothing - all lights come on but does not crank over...

Got a lift home (fetched the trusty bike ;-) ), and started testing the beetle... Here's what I've found so far:

Symptoms:
a) won't crank over - although everything else seems to power up
b) a high pitched noise is heard from what seems like the Throttle body assembly - this lasts for a while with ignition ON and then stops after a while... (can't hear it from inside the car, so I don't know if this has always been...)

Checks:
1. Everything else works and has power - it just simply wont crank..

2. plugged in VAG-COM and found the following:
Address 01: Engine Labels: 06A-906-032-AWP.lbl
Part No: 1C0 906 032
Component: 1.8l 5VT NB MT G 0102
Coding: 07510
Shop #: WSC 00066
3VWFE21C82M4xxxxx VWZ5Z0B4228244
1 Fault Found:
16395 - Bank 1: Camshaft A (Intake): Retard Setpoint not Reached (Over-Advanced)
P0011 - 35-10 - - - Intermittent
Readiness: 0000 0000

3. Checked the Instrument cluster - Groups 2x : Key ok, so I don't suspect the transponder or transponder antenna

4. EPC light and Engine lights are ON, however, I suspect they only go out once the engine runs (can't recall the normal operation) - so I don't suspect they are telling me much

5. tested the 3 fuses on the fuse box above the battery panel - all ok

6. tested the fuses in the panel (driver's door) - 4 fuses don't have power (3 marked with the engine sing and one other marked with a book) don't seem to have power with ignition ON (can't remember the numbers, and the car is standing on the other side of town ;-( ) - however one fuse marked with the engine sign does have power, and obviously VCDS could communicate with the ECU....

7. Naturally (6) made me look at the relays... - found a relay box behind the battery... containing 2 relays... one black and one gray. The Gray one was exceptionally hot... it has a huge "428" printed on it has a couple of numbers, one of which have to be a part#:
1J0 906 381B
V23134-B63-X382

I will try and find a replacement for this Relay tomorrow...

Can anyone :
i) tell me what relay this is? (ECM relay ?)
ii) if the symptoms described above could be due to the relay (I don't think that hot a relay is normal...)
iii) any other suggestions?

thanks
Stephan

[StephanT]

Update:

Went back 5 hours later... put back the Gray "428" relay... which was cold by now.... and it started up first time..

Drove it home... with MIL light, EPC ligt and ASR light on continuously...

Once I got home, I scanned the Engine again with VCDS, and found the following:

Address 01: Engine
Control Module Part Number: 1C0 906 032
Component and/or Version: 1.8l 5VT NB MT G 0102
Software Coding: 07510
Work Shop Code: WSC 00066
Additional Info: 3VWFE21C82M4xxxxx VWZ5Z0B4228244
5 Faults Found:
16395 - Bank 1: Camshaft A (Intake): Retard Setpoint not Reached (Over-Advanced)
P0011 - 35-10 - - - Intermittent
18057 - Powertrain Data Bus: Missing Message from ABS Controller
P1649 - 35-10 - - - Intermittent
18014 - Rough Road/Engine Torque Signal from ABS: Electrical Malfunction
P1606 - 35-10 - - - Intermittent
17069 - ECM Power Relay Control Circuit (J271): Open Circuit
P0685 - 35-10 - - - Intermittent
16486 - Mass Air Flow Sensor (G70): Signal too Low
P0102 - 35-00 - -
Readiness: 0000 0000

The "16486 - Mass Air Flow Sensor" I can explain, seeing as I forgot to plug that back after putting back the relay....

after the same, I tried to start the car again... nothing... same symptoms as in the first post... and the "428" relay will fry an egg...

Additionally I've noticed the aircon is no longer cold... and the connection/fuse block atop the battery was replaced about a month ago... after the aircon no longer cooled... and I was told the fuse/connections block melts... which these beeltes are known for... hmmmmm
had a look at the connection block... seems fine to me... so are the 3 fuses there...

anybody want to buy a Turbo S ?

StephanT

[dnyed]

Originally Posted by StephanT

anybody want to buy a Turbo S ?

StephanT

I do!



How many miles? Has it been taken care of? Coil packs ever replaced? MAF?

If it has run well in the past, maybe it's something minor. I don't pretend to a mechanic, but call me an optimist....

[StephanT]

It's only the frustration talking... This is generally not how I like my Sundays to pan out...

We love this one!

It's the black one and very well cared for... We replaced the coil packs just after we got it just over a year ago... (my wife is a researcher and dong a PhD here, which should be finishing up around July/August 2010 when we'll be moving back to our home in South Africa, after a stay of just over 3 years in the US (loving it) - will only be up for sale then, if you might be interested...

best,
Stephan

[HarlequinPixie]

heh. well a nice google search for "relay vw 428" leads to links that makes it sound like that could be the source of your problem (and is the ECM\power supply relay).

https://www.1stvwparts.com/part_number.html
search for part number 1j0906381b

not too expensive to replace at least, possibly not even buying the part locally, if the list price matches what they'd sell it for at a dealer.