1,2 TDI clutch/ gearbox problems

RAB said:
It's may be a brake issue, maybe the brake switch. The exclamation mark indicates a brake problem. Check the brake fluid level. But the exclamation mark will show anyway with the handbrake on. So may be nothing to do with the brakes. If the brake switch doesn't work in park mode, you won't be able to start. Try starting in neutral. May also indicate a failing clutch actuator.

Does it change gear in Tiptronic mode with the ignition on but without the engine running? If so, how many gear changes before the pump re-starts?

RAB
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Today we will change the brake switch.
If it doesn't help, I will search a clutch actuator somewhere.

Regarding the pump, when it worked (changed gear phisically) it made 4-5 gears before it restarted, so i guess the pump, and the accumulator were ok.
Now the pump works if I open the door, but as I wrote phisically doesn't change gear so perhaps you were right with the tip of the clutch actuator.
I will get back with the news.

Dan
 
If the car will not start in neutral, it's most likely that the clutch actuator is the problem. The brake switch is not required to start in neutral.

RAB
 
The news of today: brake light switch changed, sorry RAB I bought the switch when you replied, the actuator volt was out of range, we adjusted it again, then it would be possible to do basic settings everything looked nice after 6 hours, it doesn't want to start and again the same with no start in N or in S. A short check with vcds revealed 3 code. 00688 Supply Voltage Terminal 30, 00839 gearbox valve 4 N287, 00838 gearbox valve 3 N286.
Any idea?
The suspection for wiring harness still in our mind but if you say this means the clutch actuator too then next week will start with an actuator.
 
Terminal 30 is on a 68-pin connector connected to the gearbox control unit (white/green wire). This connects to N286/7 via a 14-pin connector. The gearbox actuator has its' own loom which allows it to be removed along with the wiring. It connects to the car loom via the 14-pin connector. It should be fairly easy to check continuity of car loom.

RAB
 
RAB said:
Terminal 30 is on a 68-pin connector connected to the gearbox control unit (white/green wire). This connects to N286/7 via a 14-pin connector. The gearbox actuator has its' own loom which allows it to be removed along with the wiring. It connects to the car loom via the 14-pin connector. It should be fairly easy to check continuity of car loom.

RAB
Click to expand...

Today we checked all looks good. But now there is now buzzing noise when opened the door and still the same no gear change. The error codes are the same.
 
dpalinko said:
Today we checked all looks good. But now there is now buzzing noise when opened the door and still the same no gear change. The error codes are the same.
Click to expand...

Just started the car there was a fuse a 10 amper one. I hope now it will be better than last time.
 
Hello Rab

The car run great since last Basic setting, however, I fell the creep point is not right (the engine slow down a bit before to release the clutch in eco mode for example).
So I did basic setting again today, expecting to arrive to the creep point windows, but I still have the same error message " Error Group 25 not available". I am using VCDS FRM 11.11.1
Why is that, how can I get to the creep point (I was trying 02 speed box -> 08 Measure block -> 025 Go!)
Thanks a lot
Francois
 
Hi Francois,

You have to start from scratch, all three adaptations have to be done in sequence. Otherwise, failure to perform the creep point adaptation may well indicate clutch problems if the adaptation doesn't finish. Does it start? How old is the clutch? It may well be the guide sleeve that is the problem.

RAB
 
Hi Rab
The car is old, 292K, and the speed box have been change at 200k with a second hand one 65k old. So now all this are 92k + 65k: 157.000 kms, The clutch is at maximum that old, or newer - I have this car since a year only.
The clutch is at 1.95v (was 1.93v during last basic setting 2 weeks ago, can it move 0.2v in so short time?), the Basic setting is going OK (I now use a second car with jump start cables to have a strong 13.3V during the setting, and it's going great this way), but I cannot have anything else than 'Group 025 not available' after that. As it was the case 2 weeks ago.

However, the pump is weak, it make nearly no noise compare to a newer one, and it will restart after 3 gear change (I took an accumulator from another 3L, and it was exactly the same), or more weird, the pump will start every 60 second just with the contact on. But this is the case from many month now, so I just assume this is due to the age of the pump (original, so 292k).

The car never had problems like missing gear change or no start. I just try to make it last as long as possible.
I did 200kms these last 2 weeks.

There is no leak under the car, but some oil are going out by the top, were you add the green oil (maybe I put too much oil recently). I suspect the accumulator, and I just order one.

If it's the guide sleeve that seems the problem, how long does it take to pass away ? What will be the last symptom ?
As old is the car, I would drive until it can't, then spend my time on fixing a broken down one (and for sure newer).
 
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BTW, the car have been use at 90% in Eco mode. Should I stop using the freewheeling to save the guide sleeve (I am not sure about what is a guide sleeve exactly)? Thanks.
 
Try entering '025' instead of '25'? Follow the instructions literally to the letter! It's not necessarily the guide sleeve if the adaptation is not even starting. The guide sleeve is what the release bearing runs on.

RAB
 
Hi,
The creep point adaptation is not even starting, I try several time at my first basic setting a month ago, and 2 weeks ago.
'025' not available. I must be due to an electric issue. What happen since should confirming that.

Since my first basic setting, the starter sometime just do 1/4 turn, so the engine does not start, sometime the car start normally.
This in N or P. But it was always starting after 2 or 3 try maximum.
When this happen, I hear once or twice some noise in the fuse box, so an earth can be wrong?

But today, at a red light it went wrong. At the green light, no reaction when you press the gas pedal. Engine stay idling.
In triptronic mode, engine on or off, nothing happen. Oil level OK, pump running but not as often as usually.

On VSCD, where I used to have no error, it shows today
Engine:
18060 - Lire la mémoire de défauts du calculateur de boîte de vitesses
P1652 - 35-00 -
18027 - Relais des bougies de préchauf. (J52) Rupture/court-circuit à la masse
P1619 - 35-10 - - Intermittent
17849 - Soupape recirc. gaz d´échappt(N18) Rupture/court-circuit à la masse
P1441 - 35-10 - - Intermittent
17957 - Electrov.limit. pression suralim.(N75) Coupure/Court-circuit à la masse
P1549 - 35-10 - - Intermittent
-------------------------------------------------------------------------------
Gearbox
00263 - Boîte de vitesses
27-10 - Signal implausible - Intermittent
00844 - Contacteur de détection de voie pour levier-sélecteur (F257)
35-00 - -
00843 - Potentiomètre d´avance/de retour de levier-sélecteur (G272)
16-00 - Signal hors tolérance
-------------------------------------------------------------------------------
ABS
00668 - Tension de bord borne 30
16-10 - Signal hors tolérance - Intermittent
-------------------------------------------------------------------------------
Airbags
01317 - Calculateur dans le porte-instruments (J285)
49-10 - Absence de communication - Intermittent

After deleting, only the Gearbox errors are coming back,
So all the engine, air-bag and ABS errors are due to a bad electric contact somewhere when the starter was stopping after 1/4 turn ?
BTW now the starter is normal, with 100% success when turning the key, never the starter stop after 1/4 turn like sometime before.

Do you have some suggestion, is it something known ?
What are the weak earth contact I should look, near the fuse box, or in the engine bay?
Can the basic setting been lost due to an electric shocks, when the starter was stopping after 1/4 turn for some reason?

Thank you!
 
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Long Story short, I have bad electric connections somewhere, and as errors remains about F257 & G272, it should be by there.
Do you know where are these connectors or how to access them on a Lupo? Where are the earth for both ?
Thank you very much.

Edit: it's all in SSP 221.pdf - I'll keep you posted
 
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The gearbox errors are related to the microswitches etc at the base of the gear lever.

RAB
 
Can I remove them by the top to clean/test them ?
Or I should remove the complete assembly by below, removing the exhaust system etc...?
Have you ever found a document, pdf or video, about dissembling-reassembling the whole triptronic unit?
Thank you
 
Hi Francois,

You need a copy of Elsawin. I've not done the job myself. Maybe search one of the German sites? I'll see if I can find something.

RAB
 
I have a problem with a Lupo 3L that won't start. It goes through adaptation, shifting gears nicely up to "Start Mot", I turn the key and nothing. On turning the key all the dash lights light up normally, including the preheater coil which lights for a couple of seconds then goes out. I removed the starter motor solenoid signal cable and measured the voltage when I turn the key. It never goes to 12V on turning the key. Applying 12V to the starter signal terminal directly gets the motor to turn, so the starter motor (and overheat sensor is OK). Is relay 9 the relay that feeds the starter? This relay looks good.
 
By 'starter signal terminal', presumably you mean the spade terminal on the overheat sensor? There are two relays related to starting, J53 (position 1) and J59 (position 7).

RAB
 
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Yes, I wanted to test using the overheat sensor to check that. After reading your reply I also bought a new J53, and thoroughly checked J59. Any more ideas please?

One more thing, this non-starting was intermittent, so bad that it got towed home by a motoring club. When I got in it, I did an adaptation (skipping the adjustment), and it started first time and drove fine. After parking up, it wouldn't start. So I did the adaptation again, made the adjustment, and tightened the linkage pinch bolt which was loose, we now get to "Start Mot", and there is nothing when I turn the key.
 
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