Passat (B5) :: 2002 GLX Stalled - Small Click Inside Relay Panel But No Crank


Apr 7, 2012

B5.5. Here is what happened: Was driving as usual, running low on gas. Cluster was showing zero miles left for last 10 miles. I successfully made it to the gas station. Trying to open lid - maybe on third press it popped. I thought I'm just imagining things. Drove home another 5 miles. Trying to open trunk - same as gas lid, eventually opened. I turn engine off. No dome light. None of the dome lights working. Everything else appeared still has power. Trying to open trunk again - it's dead. Trying to start the car - does not start. Trying to go home and lock with remote - not working. Lock manually and went home.

Next morning went to check fuses - all OK. Everything still not working just the way I left it. When ignition key turned - cluster comes up. When starter should crank I can hear small click inside relay panel and lighter power turned off momentarily as usual, but no crank. No messages on cluster. Dome lights, door locks by remote and starter/engine don't work. Gas lid and trunk don't work even from driver's door. If I press power lock on driver's door it will lock and immediately unlock all doors.

I did check power on fuses. Three engine related fuses don't have 12V on them. The fuses are 28, 29 and 34, or second and third up from bottom left and fourth up in second column from bottom left. Fuses itself are good.

Here I Got my first suspect: power for all 3 fuses above coming from same relay. I thought if I jump these fuses to live 12 Volts I might be able to start engine. I did jump one fuse at the time. I've heard fuel pump came up but nothing else happened. I understand that it can also be Motronic control for this relay. I pull my OBD reader, but found no codes or freeze frames. I don't have WAG reader.

But Motronic should not affect doors and dome lights (I think so but not sure), unless CAN bus shorted or something. Lights and doors can be related to Central Control and Convenience module, which supposed to be under driver seat. I had rear driver side carped wet few times when I just bought the car, but not lately, not in 6 months. I still think water damage can occur much later after exposure.

So here are mu suspects: Engine power relay, Motronic or Convenience module. It might be something else.

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So I drove my car about a mile to a friend's house and when I went to start it back up 10 minutes later, I got no start and no crank. Just a single loud relay click from the engine compartment. Tow truck tried jumping it and then thwacking the starter solenoid to try and get it going. No dice. Battery seems all good.

Had some interesting things go wrong the day before which may be related to it. First, I was tracking my MPG and fuel trim on a highway trip and the trim and fuel consumption data just stopped coming in. Speedo and RPM data was still coming down the OBDII but I just assumed that my reader took a ****. Later that night I noticed that the lights on my climate control (the manual kind) went out. Tapped on it and it came back on, but only briefly. The bulb looks shot.

No engine strangeness on the drive over or earlier in the day. I drive it most every day. Has 215,000 miles on it.

I'm guessing either a short or bad starter. FWIW, I've also been experiencing the typical starter whine after starting. Was meaning to take it off and grease it. Not sure that has anything to do with it. I also tried rotating the crankshaft to make sure the engine wasn't locked up and it does turn, albeit not incredibly easily. It does have oil on the dipstick.

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All of the dash lights came on, and I can hear the relay clicking, but that's it. I swapped the relays around, and no luck. If I let it sit a while, about an hour, it will fire right up. The battery cables are tight and free of corrosion. I am curious, since I just put in a new battery, could this be the culprit? Why will it start fine cold, but not hot? I have NEVER had an issue with this truck until now.

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About 2 weeks ago, my jetta decided it didn't want to start. Was getting symptoms of a bad ignition switch prior to this. Could get it to start one by jiggling the key. Replaced the ignition switch and now could hear the starter relay click but still no start. Yesterday, installed a reman starter and got it to start once. Could here the solenoid click when trying to start. Was reading on here or somewhere that it my be my power control relay, so took the top off to look at it and it was fine. Battery was down about 100 amps so it was replaced and still no start. Going to go see if my vag com will talk to to the ecu. Thinking about pulling the starter out and having it tested.

MK2 are so much easier.

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I turn key and get a single click. i tried jumping 2 large poles on fender solenoid and still one click no crank. i had taken off the starter and autozone tested and it passed. i checked voltages everywhere i could think of and all were as to be expected.

could it be the starter even though it passed?

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When I push the buttons, I can hear a relay click under the dash, the indicator lights come on quickly, but then they go right back off. It does not matter if I choose upper or lower heaters, and it acts the same for both driver & passenger seats.

I connected up a Snap-On computer to it yesterday. We went under the driver door module and it shows the heated seats, but no error codes were present. It displayed the heated seat as inactive. When the button is pushed, it would show active for a split second, then go right back to inactive.

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