VW Passat 2.0 TDI CR 125kW Exhaust temperature sensor (G235) defective

Hello,

The preheating light has come on for me several times, and the MFA (Multi Function Display) shows a message indicating an engine fault.
A scan using VCDS revealed that the sensor G235 is defective or malfunctioning intermittently.

I would like to replace the fuel pump, but I have read several times that there are three different types or that three fuel pumps are installed in the car.

Where am I supposed to know which donor is defective now?
A visit to Volkswagen didn't help either; the employee said that the sensor G235 is installed three times.

- Before turbochargers.
- Before DPF
- After the DPF.



The prices are expected to be around €145-€150.



Here is the excerpt from VCDS:



2 Fehlercodes gefunden:

001348 - Geber 1 für Abgastemperatur (G235)

P0544 - 000 - elektrischer Fehler - Sporadisch

Freeze Frame:

Fehlerstatus: 00100000

Fehlerpriorität: 2

Fehlerhäufigkeit: 4

Verlernzähler: 255

Kilometerstand: 158487 km

Zeitangabe: 0

Datum: 2058.14.16

Zeit: 19:24:10



Freeze Frame:

Drehzahl: 1449 /min

Geschwindigkeit: 44.0 km/h

Spannung: 14.06 V

Temperatur: 62.1°C

Temperatur: 930.0°C

Temperatur: 108.0°C

Temperatur: 78.0°C



001348 - Geber 1 für Abgastemperatur (G235)

P0544 - 000 - elektrischer Fehler - Warnleuchte EIN

Freeze Frame:

Fehlerstatus: 11100000

Fehlerpriorität: 2

Fehlerhäufigkeit: 2

Verlernzähler: 255

Kilometerstand: 158487 km

Zeitangabe: 0

Datum: 2058.14.16

Zeit: 19:24:15



Freeze Frame:

Drehzahl: 1541 /min

Geschwindigkeit: 32.0 km/h

Spannung: 13.91 V

Temperatur: 69.3°C

Temperatur: 930.0°C

Temperatur: 120.0°C

Temperatur: 90.0°C



Readiness: 0 0 0 0 0

If I were to think logically, I would assume:

Donor 1 = after turbocharger.
Sensor 2 = upstream of the DPF.
Donor 3 = after DPF.




The values would also confirm this:


Temperature: 930.0°C

The shutdown temperature at that point varies depending on the software version and is typically between 820-850°C.
Devices 2 and 3 do not achieve such values .

Are you sure this car is a standard production model?

Quote:

If I were to think logically, I would assume: Donor 1 = after turbocharger

The can find this information using the VIN and by searching via the SDC code, so it shouldn't be a problem.

Ihr meint sicher beide VOR Abgasturbolader, welcher Unterschied sollte denn eurer Meinung nach zwischen "nach Abgasturbolader" und "vor DPF" sein?

It is quite certain that the described sensor is screwed into the side of the exhaust housing of the turbocharger.
Stecker dieses Gebers trennen und entstehende Fehlermeldung prüfen ergibt Bingo oder Bull****.

Best regards, Rainer.

Ihr meint sicher beide VOR Abgasturbolader, welcher Unterschied sollte denn eurer Meinung nach zwischen 'nach Abgasturbolader' und 'vor DPF' sein?

It is quite certain that the described sensor is screwed into the side of the exhaust housing of the turbocharger.
Stecker dieses Gebers trennen und entstehende Fehlermeldung prüfen ergibt Bingo oder Bull****.

Best regards, Rainer

The sender is located behind in front of the turbocharger, but is often incorrectly referred to as being 'in front of it'.

Before the DPF, it's located at the inlet; after that, it's behind the DPF.


His car actually has 3 distributors .

Here in the redacted bid, you can see it.

Donor 1 is located behind, between the exhaust manifold and in front of the turbocharger (exhaust outlet), while the others are located before and after the DPF .

In the 170 hp PD-TDIs from Audi, it is located at the air intake.

If the image is somewhat realistic, the sender should be pointing towards the passenger seat.

Whether I'll catch it with a flashlight, mirror, and digital camera...

EDIT: Oh crap... CBBB... I have a BMR and otherwise only CBAB in the area.
EDIT2: haha They all have it .

hello,

Thank you for the answers.

The car is 100% in its original condition.

As I understand it, this refers to sensor 1 on the turbocharger.
Can I be absolutely certain about this using my VCDS device?

Hi.

930°C sounds like the upper limit of a measuring scale.

I've never seen temperatures above 810°C at the BMR; it's more like around 800°C.

Possibly, you might get lucky, and it will also display a cold reading of 930°C... in which case, it would be very easy to identify the culprit.

Top left corner, that must be it.
The CBAB definitely has a BV43 fitting – I installed one just two weeks ago.
The CBBB has a... hmmph, sorry, but it also has a Borg-Warner.


Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Quote:

Kann ich das denn mit meinem VCDS zu 100% festlegen?

You have read the G235 code. The dealer is searching for "G235" in AKTE and correctly identifies sensor 1. What's so difficult about that? Order it, replace it, and continue checking .

The picture is nonsense. The exhaust temperature sensor (G235) is located directly in front of the turbine housing. When installing it, make sure it doesn't hit anything.

@autoservice

I don't think you understand me.
I've now been to two different Volkswagen parts suppliers.
If he enters 'G235', he will have three different sensors to choose from.
If it were that simple, I wouldn't have started a thread about it.

@dieselmartin
Do you perhaps know what the product code is?

Should I just let the whole thing be for now, since the error only occurs sporadically?

Just take the 03L906088BS... that's what the internet says .

http://workshop-manuals.com/audi/a3_mk2/power_unit/4-cylinder_tdi_engine_%282.0_ltr._4-valve_common_rail%29_mechanics/exhaust_system/exhaust_gas_temperature_control_%28vehicles_with_engine_codes_cbaa_cbab_cbbb%29/removing_and_installing_exhaust_gas_temperature_sender1g235/

Was it that difficult?

But I'll tell you right away, it's incredibly cramped back there behind the turbocharger.
It's probably easiest to approach it from below.

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

The picture is nonsense. The exhaust temperature sensor (G235) is located directly in front of the turbine housing. When installing it, make sure that it doesn't touch anything.


Das kannst Du halten wie ein Dachdecker.

From the donor to the exhaust, there are only 2...3 cm, and only the exhaust turbine wheel is in between.

As you can see in the last picture, the fuel injector, as one might expect, is located BEFORE the turbocharger.

What significant differences should donors measure before the DPF and after the catalytic converter, specifically a difference of 5°C?

RedR32 hat Recht, das von mullemaus verlinkte Bild, vermutlich aus dem Teilekatalog ist wie so viele andere auch (da oft nicht zum jeweiligen Modell passend und nur schematisch) für die Tonne...
Der Link von dieselmartin kommt der Realität wesentlich näher. Das angehangene Bild im vorhergehende Posting vom mullemaus isrt eindeutig.

@mullemaus:
However, those few centimeters are crucial because the exhaust turbine experiences a significant drop in temperature due to the expansion of the exhaust gases. This results in a reading on the sensor before the Diesel Particulate Filter (DPF).