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Mon Nov 23, 2015
11:20

A buddy of mine recently tweeted something about rodent damage to his car, and it being expensive to fix, and that reminded me to get off my duff and put up this post recounting my brush with automotive mouse damage earlier this year. Mice like confined, dark, warm areas and cars are just full of those. Some of the worst stories involve mice chewing through air filters in the airbox, and the debris then getting sucked directly into the engine and causing internal engine damage. Obviously expensive, but then also a very obvious problem. At the other end of the critter damage spectrum is wiring damage. One one hand, a damaged wire or connector can be easily fixed (ok, so perhaps your mechanic would ding you with replacing an entire wiring harness, which could be expensive, but technically you can splice to repair the damage for very little cost), but on the other hand the symptoms can literally be anything and the root cause of the problem can be extremely time consuming to find, often requiring special equipment. If your mechanic spends all day chasing down electrical gremlins, that is already quite a repair bill just in labor. And often, since many shops are under such pressure to fix a car and get it out the door, the job will involve swapping out a lot of parts that are actually fine, further adding to the repair bill (the extra labor and, if the shop is trying to pull a fast one, they may even charge you for new parts that weren't necessary). Let us take my latest mousecapade as an example, and along the way we shall consider how things might have gone down, had I taken the car to a shop.

This story involves my Mk5 R32. Our neighbors across the street, wonderful folks, have a son who is a real gearhead and worked as a mechanic for a while. He appreciates cars, and I know he loves R32s. He was stationed out west and when I heard he was coming home for a visit I thought to myself "Wow he hasn't seen the R32 yet... I bet he'd like to take it for a drive". So he and I got to chatting outside one day and I told him he was welcome to take her for a spin if he'd like... of course, he took me up on the offer. We both got in, I gave him the rundown on how the DSG works, how to switch off the traction and stability control, etc. He went to start the car... and nothing. Dash lights on, but no attempt made by the starter to turn over the engine. I said "buckle your seatbelt, this car might have one of those safety interlocks" (I was pretty sure it didn't, but this was my hopeful thinking). He buckled, tried again, and the engine roared to life... then died after a split second. Now the dash was lit up like a Christmas tree and again the engine wouldn't turn over. This guy felt just awful, because he knew all too well how I must have been feeling at that moment, and even though he must have known deep down it was luck of the draw rather than anything that was his fault, he still felt like he had broken my baby.

During some previous work I had noticed a mouse nest underneath the raintray cover, that I had removed... so I immediately started to suspect some kind of rodent damage. Keep that in mind, that if that hadn't already been in my mind this whole thing could have drawn out even longer. This is the first CAN bus car I've owned, so I had to get an updated version of Ross-Tech's interface to be able to read all of the controller modules. While I was waiting for the new interface to arrive, I spent a bunch of time physically inspecting all the wiring I could get to. I tore down the rain tray and engine bay enough to inspect all the wiring and connecotrs there, I removed the bellypan to inspect everything unerneath the car, I stripped everything out of the dash to inspect as much as I could of the wiring in the dash and footwells, and I stripped out the rear luggage compartment to inspect everything in there. Absolutely no sign of any infestation, everything was squeaky clean. It took several days of free time to do all that. When my new vag-com interface arrived, I hooked it up and did a scan. There was an unmanageable number of faults logged, across all of the different modules, with no apparent rhyme or reason to them. I saved them, cleared the system, then attempted to start the car again. The engine fired up ran well. The check engine light was on and the traction control and all wheel drive were disabled. I performed another scan and this time got a much shorter list of faults, most of them complaining about the controller for the Haldex AWD module being offline. The Haldex unit is about $800, if you catch a deal on one... I certainly was not looking forward to replacing it. But with the wiring having been inspected, I was starting to come to the conclusion that it must be the Haldex unit. They are notorious for going bad, especially in areas like New England, where the climate accelerates corrosion around the connector, eventually working its' way inside the module itself. I inspected the connector on my module, and it was beautifully clean. Let's pause for a moment and consider what a shop might have done if they were working on the car. They would have started with a system scan, of course, although the car would have needed towing to the shop because it was immobile to start with. Right away you've paid for towing, and for diagnostics scan. They would have been faced with the wall of fault codes and then would have either cleared them and re-scanned (as I did), or just gone ahead and assumed that the problem was the Gateway controller module (the common link between all the CAN bus modules), and either replaced it or spent a lot of time troubleshooting it. They might have even replaced it, re-scanned, found that most of the codes were gone, and thought that they had legitimately fixed part of the problem. We're well over $1500 here so far (the gateway module is very expensive, difficult to get to, and requires special equipment to code to the rest of the system so that it will function properly), and nothing has actually been fixed or diagnosed yet. Now, faced with codes mostly pointing to the Haldex controller being offline, they might have been diligent enough to at least check for a good ground at the Haldex module plug, as bad grounds are also a common problem. In my case, the ground checked out fine. To test the CAN bus signal wires would take something better than a common multimeter, I sure didn't have the means to test them. At this point a shop could very well justify replacing the Haldex module, which is a bit of a pain if you don't either have some special or modified tools, or drop down the rear drivetrain a little bit. Even once they found that the replacement module didn't make any difference, they could easily avoid the hassle and cost of swapping the parts back out by simply charging the customer for a new module anyway. Most customers wouldn't know any better than to throw up their hands and curse Volkswagen's ineptitude over the supposed failure of such an expensive part. Two things were holding me back from ordering a new Haldex module. First, of course, was the price. Second, was the fact that there were some other seemingly unrelated fault codes that I'm sure popped up at exactly the same time. And I wasn't about to spend $800+ on a part when coincidence was part of the equation. I had other symptoms and fault codes logged that turned out to be caused by my own foolishness... I had placed one of the big power distribution fuses in the engine bay back in the wrong spot when I was doing that first round of inspection and troubleshooting, and that was causing my fresh air blower, sunroof, and headlight washers to stop working (and throw associated codes, of course). Even with that addressed, I had a strange beahavior with my fuel guage. It would only read up to, but not beyond, halfway. With a full tank of gas, the gauge would stay at half full until the actual level dropped below half, and then it would read the correct amount. There were no faults stored that seemed related to the fuel sender. How could that be related to the Haldex module going down? Electrically, they had nothing directly in common. It was about this time that someone replied to a thread I had started over on the Ross-Tech forums, suggesting that I take a look under my back seat. This fellow said that the R32 has two fuel pumps and two fuel level sending units. On one side of the car, the wiring for that fuel pump and sending unit physically runs right next to the wiring going to the Haldex control module. That sounded fantastic to me, so I took up the rear seat and removed the cover plate for the pump on the passenger side... everything looked perfect. Under the cover plate on the driver side, though, was an entirely different story. Here is what I found:

R32, mouse nest under back seat

R32, mouse damage to fuel pump and Haldex wire harnesses

Some little furry friends had made a nice, cozy home in there complete with all the terrible tasting licorice they could eat. Both wiring harnesses had been chewed through, there were only a couple of wires hanging on by a strand or two of copper. The little rascals didn't even have the courtesy to leave me enough wiring out of the connectors to splice back in. They had chewed most of the wires right up into the back sides of the connectors, so that I was faced with un-pinning each connector, uncrimping each pin, then re-crimping it onto a freshly stripped wire. A few of the wires I was able to solder, barely. Here again, once a repair shop had found this damage, they would not have wasted their time with a repair, they would have ordered whole new wiring harnesses. It looks like to replace those harnesses you'd have to drop down the fuel tank and the whole rear end a little bit, so I'm sure it would be a few hours of labor on top of the already steep cost of the harnesses themselves. Had a shop started with that seemingly unrelated fuel gauge quirk as the basis of their investigation, then they would have quickly found the real source of the problem. But worst case a customer could have been easily gouged for both replacement harnesses, replacement CAN bus gateway module, and replacement Haldex module (the new ones do not come with the Haldex clutch solenoid, so a new seal kit for that would be necessary also) as well as a couple of days labor (if they had burned most of a day chasing down the wiring and getting nowhere, as I did). This could have been a $4000 repair bill. It took a lot of blood, sweat, and tears, but I got through it without paying any cash and everything has been working perfect since then. The exposed copper wiring, where it had been chewed through, was corroded enough that I think the mouse (or mice) had been there for quite some time.

In summary, what appears to have happened was when the last of the wiring for the Haldex module finally let go (or was chewed through), it must have spiked the CAN bus signal lines and caused all the other modules to momentarily lose their grip on reality. I'm pretty lucky none of the modules were damaged, I think. For the morbidly curious, here is my scan after clearing the initial set of codes from "the incident". This was the set of relevant codes:

Saturday,30,May,2015,16:24:30:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 01: Engine Labels: 022-906-032-BDB.lbl Control Module Part Number: 022 906 032 KR HW: 022 906 032 GP Component and/or Version: R32-DQ-LEV2 G 1098 Software Coding: 0000178 Work Shop Code: WSC 01279 785 00200 VCID: 65CB9A1FAC5FCA09FD9-8030 No fault code found. Saturday,30,May,2015,16:24:48:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 02: Auto Trans Labels: 02E-927-770.lbl Control Module Part Number: 02E 300 011 CC HW: 02E 927 770 AD Component and/or Version: GSG DSG 082 1405 Software Coding: 0000020 Work Shop Code: WSC 04940 001 00001 VCID: 52A151C3CDD14DB188B-8007 No fault code found. Readiness: 0000 0000 Saturday,30,May,2015,16:21:23:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 03: ABS Brakes Labels: 1K0-907-379-MK60-A.lbl Control Module Part Number: 1K0 907 379 AB HW: 1K0 907 379 AB Component and/or Version: ESP 4MOTION MK60 0102 Software Coding: 0021128 Work Shop Code: WSC 01279 785 00200 VCID: 72E1F1436D912DB168B-8027 3 Faults Found: 01312 - Powertrain Data Bus 014 - Defective - Intermittent 01315 - Transmission Control Module 004 - No Signal/Communication - Intermittent 01324 - Control Module for All Wheel Drive (J492) 004 - No Signal/Communication Saturday,30,May,2015,16:21:53:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 08: Auto HVAC Labels: 1K0-907-044.lbl Control Module Part Number: 1K0 907 044 BS HW: 1K0 907 044 BS Component and/or Version: ClimatronicPQ35 120 1111 Software Coding: Work Shop Code: WSC 00000 000 00000 VCID: 79F3C66F30E75EE9291-802C 2 Faults Found: 01316 - ABS Control Module 004 - No Signal/Communication - Intermittent 01314 - Engine Control Module 004 - No Signal/Communication - Intermittent Saturday,30,May,2015,16:22:17:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 09: Cent. Elect. Labels: 3C0-937-049-30-H.lbl Control Module Part Number: 3C0 937 049 AJ HW: 3C0 937 049 AJ Component and/or Version: Bordnetz-SG H54 2202 Software Coding: 668F8F214004150047140000001400000008730B5C000100000000000000 Work Shop Code: WSC 01080 444 59251 Additional Info: 1K1955119E Wischer 050102 021 0501 1K0955559AF RLS 140907 046 0204 VCID: 71E3FE4F689716A9911-8024 6 Faults Found: 02092 - Enabling Heated Seat 009 - Open or Short to Ground Freeze Frame: Fault Status: 01101001 Fault Priority: 5 Fault Frequency: 1 Reset counter: 67 Mileage: 177485 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: ON Voltage: 13.40 V ON ON OFF OFF OFF 00924 - Relay for Headlamp Cleaning System (J39) 009 - Open or Short to Ground Freeze Frame: Fault Status: 01101001 Fault Priority: 4 Fault Frequency: 1 Reset counter: 67 Mileage: 0 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: OFF Voltage: 12.40 V OFF ON OFF OFF OFF 01321 - Control Module for Airbags (J234) 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177484 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: ON Voltage: 11.90 V ON ON OFF OFF ON 01314 - Engine Control Module 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177484 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: ON Voltage: 11.90 V ON ON OFF OFF ON 00466 - Control Module for Steering Column Electronics (J527) 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177485 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: OFF Voltage: 12.35 V OFF ON OFF OFF OFF 01309 - Power Steering Control Module (J500) 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177484 km Time Indication: 0 Date: 2005.09.13 Time: 31:63:63 Freeze Frame: ON Voltage: 11.90 V ON ON OFF OFF ON Saturday,30,May,2015,16:22:43:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 0F: Digital Radio Labels: 8E0-035-593-SIR.lbl Control Module Part Number: 8E0 035 593 H HW: 8E0 035 593 H Component and/or Version: SDAR SIRIUS H06 0080 Software Coding: Work Shop Code: WSC 00000 000 00000 VCID: 2E592533B9294951CC3-807B 1 Fault Found: 02635 - Tuner Not Enabled/Activated 000 - - Freeze Frame: Fault Status: 01100000 Fault Priority: 7 Fault Frequency: 5 Reset counter: 190 Mileage: 172695 km Time Indication: 0 Date: 2000.00.00 Time: 18:48:00 Saturday,30,May,2015,16:23:03:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 15: Airbags Labels: 1K0-909-605.lbl Control Module Part Number: 1K0 909 605 AB HW: 1K0 909 605 AB Component and/or Version: 6T AIRBAG VW8R 034 8000 Software Coding: 0013908 Work Shop Code: WSC 01269 785 00200 Additional Info: 1K0959339G BF-Gewichtsens. 007 0007 Additional Info: Geraet 00200 VCID: 6CDDEF3B4FB5FB41A27-8039 1 Fault Found: 01312 - Powertrain Data Bus 014 - Defective - Intermittent - MIL ON Saturday,30,May,2015,16:25:40:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl Control Module Part Number: 1K0 953 549 AQ HW: 1K0 953 549 AQ Component and/or Version: J0527 036 0070 Software Coding: 0012122 Work Shop Code: WSC 01279 785 00200 Additional Info: XXXXXXXXXXX E0221 002 0010 Additional Info: Geraet 00200 VCID: 0103AE8F58370629611-8054 No fault code found. Saturday,30,May,2015,16:23:44:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 17: Instruments Labels: 1K0-920-xxx-17.lbl Control Module Part Number: 1K6 920 974 D HW: 1K6 920 974 D Component and/or Version: KOMBIINSTRUMENT VDD 1216 Software Coding: 0007203 Work Shop Code: WSC 01052 444 68459 VCID: 356B0A5F5C7F7A898D9-8060 2 Faults Found: 01315 - Transmission Control Module 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177485 km Time Indication: 0 Date: 2000.00.00 Time: 01:02:16 01312 - Powertrain Data Bus 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 2 Fault Frequency: 8 Reset counter: 99 Mileage: 177484 km Time Indication: 0 Date: 2000.00.00 Time: 12:06:41 Saturday,30,May,2015,16:24:06:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 19: CAN Gateway Labels: 1K0-907-530-V3.clb Control Module Part Number: 1K0 907 530 L HW: 1K0 907 951 Component and/or Version: J533 Gateway H07 0052 Software Coding: ED831F075003020000 Work Shop Code: WSC 01279 785 00200 VCID: 30653B4BA31D5FA1DEF-8065 4 Faults Found: 01312 - Powertrain Data Bus 014 - Defective - Intermittent Freeze Frame: Fault Status: 00101110 Fault Priority: 1 Fault Frequency: 1 Reset counter: 255 Mileage: 177484 km Time Indication: 0 Date: 2000.00.00 Time: 12:06:43 01315 - Transmission Control Module 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00110100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177485 km Time Indication: 0 Date: 2000.00.00 Time: 01:02:18 01324 - Control Module for All Wheel Drive (J492) 004 - No Signal/Communication Freeze Frame: Fault Status: 01100100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 59 Mileage: 177485 km Time Indication: 0 Date: 2000.00.00 Time: 00:11:57 00466 - Control Module for Steering Column Electronics (J527) 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00110100 Fault Priority: 2 Fault Frequency: 1 Reset counter: 99 Mileage: 177485 km Time Indication: 0 Date: 2000.00.00 Time: 00:00:01 No response from AWD controller (address 22) Saturday,30,May,2015,16:27:12:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb Control Module Part Number: 1K6 920 974 D HW: 1K6 920 974 D Component and/or Version: IMMO VDD 1216 Software Coding: Work Shop Code: WSC 00000 000 00000 VCID: 356B0A5F5C7F7A898D9-8060 No fault code found. Saturday,30,May,2015,16:27:35:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 37: Navigation Labels: 1K0-919-887-MFD2.lbl Control Module Part Number: 1K0 919 887 G Component and/or Version: Navigation 0050 Software Coding: 0000101 Work Shop Code: WSC 01279 785 00200 VCID: 3D7B127F644FA2C9459-8068 No fault code found. Saturday,30,May,2015,16:27:49:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 42: Door Elect, Driver Labels: 1K0-959-701-MIN3.lbl Control Module Part Number: 1K0 959 701 M HW: 1K0 959 701 M Component and/or Version: Tuer-SG 006 120A Software Coding: 0001077 Work Shop Code: WSC 01279 785 00200 VCID: 3875036B4B6D87E196F-806D 2 Faults Found: 00466 - Control Module for Steering Column Electronics (J527) 004 - No Signal/Communication - Intermittent 01321 - Control Module for Airbags (J234) 004 - No Signal/Communication - Intermittent Saturday,30,May,2015,16:28:09:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb Control Module Part Number: 1K1 909 144 M Component and/or Version: EPS_ZFLS Kl.141 H08 1901 Software Coding: Work Shop Code: WSC 00000 028 00001 VCID: 356B0A5F5C7F7A898D9-8060 No fault code found. Saturday,30,May,2015,16:28:30:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 46: Central Conv. Labels: 1K0-959-433-MAX.clb Control Module Part Number: 1K0 959 433 CT HW: 1K0 959 433 CT Component and/or Version: KSG PQ35 RDK 052 0221 Software Coding: 139006885103281B0904058FB0080A04889C00 Work Shop Code: WSC 00000 785 00200 Additional Info: Sounder n.mounted NGS n.mounted Additional Info: IRUE n.mounted VCID: 040DA79B472513014A7-8051 1 Fault Found: 00466 - Control Module for Steering Column Electronics (J527) 004 - No Signal/Communication - Intermittent Freeze Frame: Fault Status: 00100100 Fault Priority: 4 Fault Frequency: 1 Reset counter: 99 Mileage: 177485 km Time Indication: 0 Date: 2000.00.00 Time: 00:00:01 Saturday,30,May,2015,16:28:45:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 47: Sound System Labels: 3C0-035-456.lbl Control Module Part Number: 1K6 035 456 B HW: 1K6 035 456 B Component and/or Version: 08K Audioverst. 0006 Software Coding: Work Shop Code: WSC 00000 000 00000 VCID: 2B5F2C278A3B3C79EBD-807E No fault code found. Saturday,30,May,2015,16:29:02:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 52: Door Elect, Pass. Labels: 1K0-959-702-MIN3.lbl Control Module Part Number: 1K0 959 702 M HW: 1K0 959 702 M Component and/or Version: Tuer-SG 006 120A Software Coding: 0001076 Work Shop Code: WSC 01279 785 00200 VCID: 3973066F70679EE9691-806C 2 Faults Found: 00466 - Control Module for Steering Column Electronics (J527) 004 - No Signal/Communication - Intermittent 01321 - Control Module for Airbags (J234) 004 - No Signal/Communication - Intermittent Saturday,30,May,2015,16:29:20:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 55: Headlight Range Labels: 1T0-907-357.lbl Control Module Part Number: 1T0 907 357 Component and/or Version: Dynamische LWR 0003 Software Coding: 0000004 Work Shop Code: WSC 01279 785 00200 VCID: 74EDF75B178523817A7-8021 1 Fault Found: 01312 - Powertrain Data Bus 014 - Defective - Intermittent Radio, address 56, Stuck on "CAN init..." while buttons 02, 18, 1a, and 16 enable/disable, and radio in car repeatedly turns on and off. Eventually received error dialog "VCDS: Session Unreliable", "Too Many Communications Errors to Continue!" Saturday,30,May,2015,16:32:06:15884 VCDS Version: Release 14.10.2 (x64) www.Ross-Tech.com Address 65: Tire Pressure Labels: 3C0-959-433-65.lbl Control Module Part Number: 1K0 959 433 CT HW: 1K0 959 433 CT Component and/or Version: RDK 0450 Software Coding: 0100101 Work Shop Code: WSC 01279 785 00200 VCID: 040DA79B472513014A7-8051 1 Fault Found: 00625 - Vehicle Speed Signal 008 - Implausible Signal - Intermittent Freeze Frame: Fault Status: 00101000 Fault Priority: 4 Fault Frequency: 1 Reset counter: 99 Mileage: 177484 km Time Indication: 0 Date: 2000.00.00 Time: 12:06:42


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