Pa 3C BMR Won't Start: Error Code 004160 (Solution)

Sure, here's the translation of the text from German to English:

"The following situation:"

A vehicle belonging to a friend broke down while driving. When I arrived to help, it started again after 15 minutes, but with occasional misfires. The error memory shows the following:

Code:

Adresse 01: Motor       Labeldatei: RKS\03G-906-018-BMN.lbl    Steuergerät-Teilenummer: 03G 906 018 ER    HW: 03G 906 018 S   Bauteil und/oder Version: R4 2.0l PPD1.2 G    4367                  Codierung: 0000072             Betriebsnummer: WSC 33464 133 95297                       VCID: 79FC6E3Exxxx 2 Fehler gefunden: 001137 - Drucksensor 1 für Abgas (G450): unplausibles Signal                P0471 - 006 - Kurzschluß nach Plus - Sporadisch              Umgebungsbedingungen:                     Fehlerstatus: 00000001                     Fehlerpriorität: 1                     Fehlerhäufigkeit: 5                     Verlernzähler: 40                     Kilometerstand: 84133 km                     Zeitangabe: 0                     Datum: 2011.05.27                     Zeit: 16:17:47              Umgebungsbedingungen:                     Drehzahl: 0 /min                     Drehmoment: 0.0 Nm                     Geschwindigkeit: 0.0 km/h                     Druck: 0.0 mbar                     Text:      -84    mbar                            Text:  128    C                                    Temperatur: 16.5°C 004160 - Versorgung Einspritzventil(e) A: elektrischer Fehler im Stromkreis                P1040 - 006 - Kurzschluß nach Plus - Sporadisch              Umgebungsbedingungen:                     Fehlerstatus: 00100001                     Fehlerpriorität: 4                     Fehlerhäufigkeit: 1                     Verlernzähler: 40                     Kilometerstand: 84132 km                     Zeitangabe: 0                     Datum: 2011.05.27                     Zeit: 16:07:09              Umgebungsbedingungen:                     Drehzahl: 2304 /min                     Drehmoment: 352.0 Nm                     Geschwindigkeit: 58.0 km/h                     Batteriespannung: 114.6 V                     Batteriespannung: 112.6 V                     Batteriespannung: 107.6 V                     Batteriespannung: 109.6 V Readiness: Nicht verfügbar

I cleared the error codes and was wondering whether we should drive it or have it towed.

After traveling for 50 meters, the journey came to an end – it was towed away.

It started up again at home, but it was sluggish. After about 10 seconds, it stopped.

Error read again: Error 4160 is present again.

How do I start searching effectively now?

Is the error code 4160 now the primary reason why it won't start, or is it only the cause of the intermittent issues, suggesting that there might be another underlying problem?

Hello,

I only see the error code 001137 with defective sensors or cable problems.

The part number 004160 is likely the cause of the starting problem; it could be due to damage from rodents or something like "foreign objects twisted into/rubbing against the wiring harness."

I would disconnect the connector at the engine control unit and then use a multimeter to measure the voltage at the pins on the pressure sensor units.

Best regards, Rainer.

I have already exposed the M TCU as much as possible. Tomorrow morning, I will first remove the breakaway screws from the TCU housing, and then we'll see if anything has dissolved or deteriorated on that part.
Possibly there's an issue with the PD cable harness.

So far, at least from a purely visual inspection, I haven't noticed anything wrong with the wiring harness except for its poor quality.

Wiring harness or PCB (Printed Circuit Board) itself. Both are not uncommon .

Okay, BM, please remove the valve cover and disconnect all the connectors from the PD elements. Then, using a multimeter, measure the resistance between the contacts of each element and the engine ground. One of the elements will have a short circuit to ground, and you'll need to replace that one. At the same time, always replace the wiring harness in the head as well.
Best regards, Jörg.

Quote:

a short circuit to ground will occur at an element

I also considered that, but the error code indicates a "short circuit to positive." It would be interesting to see if it's related, but I think that with an electrically faulty power drive (PD) unit, the motor would run very poorly, if at all, even when idling.

Best regards, Rainer.

Hello,

Brief update:

Visual inspection of the external cable harness (positive wire) for all 4 Power Distribution Units revealed no issues.

Pass-through inspection of the external cable harness (negative/ground) for all 4 power distribution units also revealed no issues.

"No short circuit detected on the vehicle body or on the common positive line of the power supply units (PSUs)."

I haven't removed the valve cover yet due to time constraints, but I have checked the resistance of each individual pressure sensor (from the outside) --> all 4 show a reading of 197-200 kOhms.

In addition (even though it may not be related to the error), I opened the coolant filter --> The filter was completely full, and the pre-pump is running during the start attempt.

What's the best way to proceed from here?

I would also be interested to know from which specific situation or type of problem the engine simply won't start at all.

Hi, I've encountered this error many times. However, I always measure directly at the components. If there's nothing to measure there, check the wiring harness near the starter motor. There are often frayed cables in that area. Best regards, Jörg.

Quote:

I also thought about that, but the error is a "short circuit to positive." It would be interesting to see if it's still related to that

.

Could it be that if a sporadic short circuit occurs in the presumably common positive line (or in the power distribution unit itself), all power distribution units are switched off?

Tomorrow I will continue searching as soon as I have time.

If my suspicion proves to be correct that a faulty power distribution unit (PDU) can lead to complete system failure simply because of cost-cutting measures like omitting separate wiring, it would once again be a testament to the poor design choices made by the engineers, and the individual PDU shutdown feature in case of a defect would become relatively pointless.

If my assumption proves to be correct, that a defective power distribution unit (Pd) can lead to a complete system failure, simply because people once again try to save money in the wrong place and forgo separate wiring, this would once again be a testament to the poor design choices, and the individual Pd shutdown in case of a defect would be relatively pointless.


That's just how it is.

mullemaus wrote:

That's how it is.

Right. I had the same problem last year with a 170HP DPF. One element had a short circuit, and nothing worked anymore.

Hello BM, disabling all P-D elements is purely a safety measure. The control unit is short-circuit resistant, but it cannot determine which cylinder has a short circuit to ground, so it shuts down all elements, rendering everything inoperable. Replacing the internal wiring harness of the cylinder head is also intended to prevent contact problems.
Best regards, Jörg.

First of all, thank you for the helpful tips.

Even though it's Sunday, I normally checked the PD cable harness (from the outside) for continuity to ground today. Contact 4 has a short circuit to ground with approximately 100 ohms. Contact 9 shows infinite resistance.

Contacts 4 and 9 are knotted together on the outer cable harness and run as a single cable to the control unit (STG).

Okay, I've found the errors. Now it just comes down to whether the wiring harness or the power control module (PCD) is faulty.


If it were my car, I would first replace the twisted connections at terminals 4 and 9 with connector plugs. This would make it possible to disconnect the circuit causing the short circuit, allowing the vehicle to be maneuvered on two cylinders, considering that this potential source of error occurs four times.

It's not even possible to use the starter motor to nudge the vehicle off the road.

If it were my car, I would remove the cover, disconnect the plugs from the PPDEs (Power Distribution Control Modules), and take measurements. The cover has to be removed anyway, regardless of what the problem is. Why tear apart a potentially perfectly good wiring harness in the process?

In 99% of cases, it's probably the PPDE.

Hello,

Problem solved.

As expected, one of the photodiodes was defective, or rather, the supposed positive pin had a short circuit to ground.

During this process, the remaining 3 pressure-positive devices (PPds) were cleaned using ultrasound. The decision was made to not replace the remaining 3 PPds for understandable reasons.

Let's see if, when, and where the cart will break down next.

Quote:

If it were my car, I would remove the cover, disconnect the plugs from the PPDEs, and take measurements. The cover has to be removed anyway, regardless of what the problem is. Why tear apart a potentially perfectly intact wiring harness in the first place?

I devised this more as a precautionary measure for the next PPD failure, which is almost certain to happen eventually. This would allow the vehicle to continue running on two cylinders, or at least prevent being completely stranded. The original connection point is already poorly made and slightly corroded anyway, so there's nothing to lose by modifying it.

Because I personally hate unreliable cars like the plague.


Here's a tip for a quick diagnosis (edit: Volkswagen Passat 2006, engine code BMR) of error code 004160 without disassembling any parts:

Code:

-- Stecker am Zylinderkopf abdrehen -- Am Zylinderkopf den Kontakt 4 und 9 einzeln gegen Masse auf Durchgang        überprüfen. Wenn Durchgang vorhanden  --> PPD oder Kabelbaum innen defekt. Eine Überprüfung des Kabelstrangs im Motorraum auf Kabelbrüche oder Marderverbiß kann dann entfallen.

And thank you again for your help.