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VW Jetta 2006 1K1 Steam Coming From The Radiator & Misfired With RPM

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I do NOT need help, I repaired this vehicle!
Proof of concept and how I solve the customer issues:
History and background:
This customer contacted me because of other shops knowing my reputation. These other shops performed very poor work and this customer spent lots of money for nothing. This vehicle came to him as a used purchase to either keep or sell.

Parts replaced form other shops:
Ignition coils (used)
Oil pan (new)
Turbo charger (used)
Throttle body (used)
Radiator (used)
Right headlamp assembly (used)

The first scan was an investigation of what faults were currently stored within the network After that first scan, faults were deleted and scanned again with an estimate for repairs. I noticed some steam coming from the radiator when the cooling fans engaged the engine did run rough and misfired with RPM increase. The customer also discussed the high beam circuit incorrectly operating and high beams would not engage with the manual switch. Once the customer had the money, the vehicle was authorized to repair.

Next step and before any repairs began, another complete scan and acquired pre-labels to be converted from encrypted to readable text as a better build and adding the missing pieces into the data stream.

Parts I replaced:
G26 crank position sensor
Oil separator on valve cover
New radiator

Noticed from the previous repairs, some of the harness (loom) connection locks were damaged or missing. The customer is now aware of the earlier poor workmanship and new oil leak developed at the rear of the vacuum pump (cylinder head)
Those connections are:
The MAF
The Turbo boost sensor
The HVAC pressure sensor
The ignition coil connections (4)
All plastic shells above require replacement.

After completed (authorized) repairs, adaptations and basic settings were performed and successful. This direct injection engine runs quite well now.

The last complaint was the high beam circuit that would not operate with:
The key on and engine running
The light switch in the normal (on) position

Tools used:
Legitimate VCDS with new labels created
ODIS service as a test
ODIS engineering to measure for flash updates (non required)
Oscilloscope
ElsaWin

So my question to any member that wants to “think” about this last question. How and what is the procedure to test and possibly repair the high beam lighting complaint?

With enough answers I will post the final solution and final scan.

Here is a chance to learn, set a standard and reverse engineer this vehicle with all the other VAG group posts that are missing important details.
Log-RICHARD 01-3VWKJ31K16M836071-210330km-130693mi.txt
File Type: .txt
Downloaded: 13 times
Size: 13.53 KB


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