Engine Management Code

[GTi-Tecnix]

I bought a DSG MK5 Golf GTI in SUMMER 2016. I noticed soon as I drove on the motorway was not pulling as it should and very sluggish and the engine management light was on dash. The engine was also jerky and shaky. After a recent change of coils and plugs including oil change, I now have been consistently getting the engine management light on dash. I got it diagnosed and code is showing the following flag:

EVAP Emission Control Sys incorrect flow P0441 Lower Limit Reached

I noticed that two of the engine cover rubber stoppers that go under the two back ports of the cover are broken. Also the fuel pressure regulator is snapped as you take the cover off. Do these have a say in the issue?

I'm also getting pops in the rear exhaust when I start the car of a morning.

[pudding]

Evap fault codes are very common and the fix is usually one or more of the following:

1) Carbon canister (behind offside headlight)
2) N80 purge valve (under engine cover, on intake manifold)
3) Worn seal in petrol cap
4) Carbon can to tank vent hose

I ended up having to replace all of those things and the code eventually went.

You mean the pressure sensor on top of the mechanical fuel pump has snapped?  Very common.  I think that is due to clumsy removal of the engine cover.  You can't buy that part seperately from VW.  Best bet is to get a used pump that has the sensor still intact and harvest it for your pump.

Rubber stoppers - still available from VW.

Pops in the exhaust.  That would need further investigation. Is the car standard?  Immediately after it's started, or during warm up? On the over-run?

[lukemk5gti]

@Pudding is right and this is what VW will recommend too.

BUT

This issue arrises from filling the fuel tank to the max, the activated carbon cannisters job is to filter harmful gasses from the fuel tank but by brimming it, fuel can often travel into the PAC and saturate it which will throw up the fault once more. (This is all based on what VW have told me and general consensus on the forum).

When VW insisted I replace mine, I demanded a warranty that this issue wouldn't arise as soon as I brim the tank again but they were unable to offer it.

Moral of the story is, if you replace it, it can come back so why bother? I cleared the fault with VCDS and it hasn't come back in 2 years after the first 4 or 5 clears.

Separately, those rubber bumps I guarantee were at the back of the cover (toward the windscreen). More heat generates here and the rubber naturally splits, it happens to everyone and you can replace them for about £1 each. I think the part number is in my build thread - http://www.mk5golfgti.co.uk/forum/index.php/topic,89715.msg907250.html#msg907250

[GTi-Tecnix]

@Pudding- Yes when I start the car in the mornings during the warm-up the exhaust it makes "pops" after a few minutes.

The two rubber grommets are snapped and sometimes the intake manifold cover is si stubborn to take off - even after greasing the damn thing!

Since I changed the plugs to NGK Irridum recently, I can no longer hear the dump valve releasing excess gas (hissing noise) when I press my foot on the pedal whilst stationary. It can now only be heard when driving which is a mystery to me!

[GTi-Tecnix]

Hi do you have part VW numbers please? 

Evap fault codes are very common and the fix is usually one or more of the following:

1) Carbon canister (behind offside headlight)
2) N80 purge valve (under engine cover, on intake manifold)
3) Worn seal in petrol cap
4) Carbon can to tank vent hose

I ended up having to replace all of those things and the code eventually went.

You mean the pressure sensor on top of the mechanical fuel pump has snapped?  Very common.  I think that is due to clumsy removal of the engine cover.  You can't buy that part seperately from VW.  Best bet is to get a used pump that has the sensor still intact and harvest it for your pump.

Rubber stoppers - still available from VW.

Pops in the exhaust.  That would need further investigation. Is the car standard?  Immediately after it's started, or during warm up? On the over-run?

[pudding]

@Pudding is right and this is what VW will recommend too.

BUT

This issue arrises from filling the fuel tank to the max, the activated carbon cannisters job is to filter harmful gasses from the fuel tank but by brimming it, fuel can often travel into the PAC and saturate it which will throw up the fault once more. (This is all based on what VW have told me and general consensus on the forum).

When VW insisted I replace mine, I demanded a warranty that this issue wouldn't arise as soon as I brim the tank again but they were unable to offer it.

Moral of the story is, if you replace it, it can come back so why bother? I cleared the fault with VCDS and it hasn't come back in 2 years after the first 4 or 5 clears.

Separately, those rubber bumps I guarantee were at the back of the cover (toward the windscreen). More heat generates here and the rubber naturally splits, it happens to everyone and you can replace them for about £1 each. I think the part number is in my build thread - http://www.mk5golfgti.co.uk/forum/index.php/topic,89715.msg907250.html#msg907250

Interesting!  I can cram fuel into mine until it starts pouring on the floor and the EVAP fault code never comes on 

[pudding]

I'm afraid not mate.  Google or your dealer 

Hi do you have part VW numbers please? 

Evap fault codes are very common and the fix is usually one or more of the following:

1) Carbon canister (behind offside headlight)
2) N80 purge valve (under engine cover, on intake manifold)
3) Worn seal in petrol cap
4) Carbon can to tank vent hose

I ended up having to replace all of those things and the code eventually went.

You mean the pressure sensor on top of the mechanical fuel pump has snapped?  Very common.  I think that is due to clumsy removal of the engine cover.  You can't buy that part seperately from VW.  Best bet is to get a used pump that has the sensor still intact and harvest it for your pump.

Rubber stoppers - still available from VW.

Pops in the exhaust.  That would need further investigation. Is the car standard?  Immediately after it's started, or during warm up? On the over-run?

[unzippy]

This issue arrises from filling the fuel tank to the max, the activated carbon cannisters job is to filter harmful gasses from the fuel tank but by brimming it, fuel can often travel into the PAC and saturate it which will throw up the fault once more. (This is all based on what VW have told me and general consensus on the forum).

Likewise, brimmed it past 3 clicks once and light came on.  Cleared it and filled twice since and never been back.

[GTi-Tecnix]

I think I've managed to find the part numbers for

• Carbon/Charcoal Cannister: 1K0 201 797 AE / 1K0 201 797 AB / 1K0 201 797 R
• N80 PURGE SOLENOID VALVE OE: 06E906517A

I'm afraid not mate.  Google or your dealer 

Hi do you have part VW numbers please? 

Evap fault codes are very common and the fix is usually one or more of the following:

1) Carbon canister (behind offside headlight)
2) N80 purge valve (under engine cover, on intake manifold)
3) Worn seal in petrol cap
4) Carbon can to tank vent hose

I ended up having to replace all of those things and the code eventually went.

You mean the pressure sensor on top of the mechanical fuel pump has snapped?  Very common.  I think that is due to clumsy removal of the engine cover.  You can't buy that part seperately from VW.  Best bet is to get a used pump that has the sensor still intact and harvest it for your pump.

Rubber stoppers - still available from VW.

Pops in the exhaust.  That would need further investigation. Is the car standard?  Immediately after it's started, or during warm up? On the over-run?