Throttle body - connector replacement, fun and games

A6 All/ S6 All
#1

So we had a bunch of issues with the throttle body connector, a replacement connector, some manifold repair and refacing and I have had 2 weeks of happy driving.

Then this morning ESR ESP and limp mode.

012342 - Throttle Controller 2 (J544)
P3036 - 002 - Low Voltage at Basic Setting
Freeze Frame:
Fault Status: 01100010
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 112254 km
Time Indication: 0

         Freeze Frame:
                RPM: 101 /min
                Load: 100.0 %
                Speed: 0.0 km/h
                Temperature: 12.0°C
                Temperature: 14.0°C
                Absolute Pres.: 990.0 mbar
                Voltage: 10.033 V

012328 - Angle Sensor 2 for Throttle Drive 2 (G298)
P3028 - 008 - Implausible Signal
Freeze Frame:
Fault Status: 01101000
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 112254 km
Time Indication: 0
Date: 2018.07.17
Time: 07:35:17

         Freeze Frame:
                RPM: 1634 /min
                Load: 40.0 %
                Speed: 0.0 km/h
                Temperature: 17.0°C
                Temperature: 18.0°C
                Absolute Pres.: 990.0 mbar
                Voltage: 11.557 V

reset the throttle body plugs (unplug/replug) Cleared the codes and drove around the block

no warning lights but this fault remained,

1 Fault Found:
012342 - Throttle Controller 2 (J544)
P3036 - 002 - Low Voltage at Basic Setting
Freeze Frame:
Fault Status: 01100010
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 112257 km
Time Indication: 0
Date: 2018.07.17
Time: 19:07:16

         Freeze Frame:
                RPM: 643 /min
                Load: 24.3 %
                Speed: 0.0 km/h
                Temperature: 85.0°C
                Temperature: 24.0°C
                Absolute Pres.: 990.0 mbar
                Voltage: 14.224 V

It remained after each clear. I then did a Throttle body recalibration and cleared the code…this seem to fix it.

Question is why…why did it pop up - does this mean my TB is on the way out? anyone had experience with these codes.

Many thanks

#2

The throttle bodies need to go though the adaption prossess. There is a complete prossess in Vag com that you can completely adapt them. Its recommended to do anytime you reset the ECU. Another good thing to do is to turn the key forward before you start the car and wait about 20seconds you can hear the throttle body adapting.

The code could still be there due to a possible still bad transfer connection. Chances are good the first times it was due to low voltage along with the other issues. the rpm the code is tripped at looks like its tripped during the starting phase. Keep an eye on the batter voltage that might help

#3

Yeah cheers - carried out reset procedure, replaced the battery just last month - we have had issues with this area for a while. Are the TBs a normal thing that fails / needs replacing? noting they are about $1500 per side my money, im wondering if a second hand one will be ok??

#4

I think there is a chance that they are the same as the B5 S4 throttle body. You can probably get those crazy cheap.

#5

Did you replace the connectors and wires on both throttle bodies?

#6

all the faults and issues have been on side 2, which was the side of the damaged plug and dodgy wiring etc

#7

Seems the wiring is at fault - loom issues or troubles which are proving hard to find :frowning:

#8

Wow this isn’t the first report of wire loom issues related to the throttle body. Can you let us know where you found the issues in the length of the loom. Maybe there is a bad spot heat wise.

On the S4 the SAI fuse blows because the wire loom on the passenger side right above the manifolds gets hot and then the outer covering for the wires brakes apart and causes a short after enough time.

#9

Yes, the entire engine bay!

The wires to my knock sensors were crumbling. I had to splice in about 12 new ends about a year and a half ago.

#10

WOW. I wonder if all cars see this or if its just climate related. That’s a lot of wire work.

#11

No real progress here, cars still in the shop.

They have pushed it around to an Auto electrical specialist - The most frequent issue is a low voltage to one throttle body (right hand side as you look at the engine) on initial start. This doesnt change if you change the throttle bodies from one side to side.

They cant seem to work out what causes it…any ideas…??

#12

So during the digging they found that the Ecus were replaced in 2014 . . . Would there be any reason for this??

Still no solution for the issue.

#13

The ECUs power the 02s and have the amps for the coils. The ECUs are drivers for several things. They could have gone bad and that is part of what I Was going to suggest there is a chance that the ECU also runs the voltage to the throttle body.

#14

yes that is the back up plan(ECUs), they are going to re wire that part of the loom to the TB and see if we have luck there.

#15

So update. The autosparkie found the plug from the ecu to the throttle body was not all the way home. That part of the loom was messed with anyway so they decide to create a new part from plug to plug, replacing all the pins etc also. They have given me the car back without billing me to try it out. They have not been able to get the fault to reappear for a number of weeks. But wanna be sure before we go further.