PROBLEM HAS BEEN SOLVED (AT LEAST UNTIL THE PROBLEM RESURFACES???)*******************
I have done lots of research however other people's cases don't exactly match mine, nor do their solutions resolve my problem.
I will discuss information of the vehicle, the symptoms, as well as some relevant history of the car that I think might be related.
It is my 2005 VW Passat TDI. It's the b5.5 engine code BHW. It just turned over 120,000 miles.
My symptoms are:
Intermittent non-functioning windows, locks, and interior lighting (the red lit buttons on the window and door controls on all the doors). As well as every now and then, the instrument cluster will flash every light on, then (if at night and i have the lights on, will turn off the cluster illumination (indigo/red), and the needles will all fall down to zero(rpm, mph, fuel, temp) and then go back to normal, with the only thing reset on the dash is the regular trip mileage and time being reset, this will also happen when the car is off, ive never witnessed it, but ive come outside to get in my car with the clock at a very wrong time and 0 miles on the trip. the lcd seems unaffected, those trips stay recorded.
The problems is that they are all interconnected in different ways. for example a usual day looks like this:
I start the car and everything works, then suddenly the interior button lights turn off on the doors only (and steering wheel controls but ill explain more on this later). At this point the window controls will not work UNLESS I hit either the lock or unlock door button first, then the windows can be controlled for that respective door (I can't control the passenger doors from the driver window controls, however if i press the lock or unlock button on the passenger door i can then control that window from that door). Auto up/down function does not work in this scenario, I have to hold down the buttons to keep the window moving. The whole (press the unlock button to get them working again trick works but after a while i will lose control of the windows completely, HOWEVER, if i turn the car off i can then control that doors respective window again, and i can ALWAYS get out, and hold the key in the door to the unlock/lock positions to control the windows. This is the main symptom, and i will now discuss the history of the car that might help you get an understanding of what may be wrong.
First and foremost, I did a fog light retrofit. I bought the relay, and switch from a junkyard, bought the assemblies online, and wired them in as stock as can be, using information on this forum, I had a **** up when i ran the wire that goes to the foglights through the grommet for the hood latch release cable, and did a poor job of it, I realized this when it started raining and my footwell started flooding. It was a terrible experience and I definitely learned from it. I proceeded to redo the grommet properly, test it, and get rid of the water, i dried it out as best i could, then took a shop vac to the carpet, and even employed some cat litter to fully dry out the carpet. I mention this because I already checked the ccm, and even tho its poor placement, the box it sits in kept the water out, there is no visible damage, and when i swapped it into my other 2005 passat TDI which is absolutely 100% stock, it works.
I also did a Multi-Function Steering Wheel retrofit, using information on this forum as well as information from TDIClub. I did it as stock as possible, I bought a pre-made wiring harness from germany for like ~$80, the relay from online as well as the steering wheel and air-bag, and followed all instructions properly and its as stock of a job as can be. both of these retrofits happened months before the symptoms started showing.
Another issue is dome lights and the driver door. Pretty much the entire time i've owned the car, its been shifty about the dome lights and when I open the door, it's never a problem when the door is closed, however when the door is open, it would maybe turn off for half a second or maybe more, or maybe there would be a delay in when the light turns on. This was this way for a long time until these symptoms started showing up it's now worse, as i explain later in the post, but this in particular was the state in the past
The symptoms started showing first as a intermittent loss of the steering wheel controls and interior button lights. then it became more and more frequent, then the instrument cluster started happening, and so on. Now, maybe a third of the time the instrument cluster does its thing, the screen in the center will show the "emissions workshop" and the computer stores a code, the readout is:
1 Fault Found:
188058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 000 - -
The most current stage involves all of this including some issues with doors not being sensed properly, as well as the interior lights not lining up with the message on the instrument cluster about doors, whether it be the door open light, or when you get past a certain speed it telling you which door is open. It happens with all doors, sometime it thinks the driver door is open when it is closed, sometimes the passenger doors, now and then the interior lights will turn off, as if the doors are closed, but the car keeps beeping at me as I drive off, and the message shows (__ door open blah blah) and the only way to shut it up is to stop, take the key out and restart the car without opening a door. If all of this happens I also lose control of locks, if i press my doors lock button, my door lock goes down, then back up. Sometimes the door locks are up while at speed, and then they all go back down, the next time i turn the car off and get out, the alarm goes off.
Things I have checked:
CCM, visual inspection as well as trying it in an identical passat, aside from exterior/interior color, and the fact that it is 100% stock,
CCM wiring, visual inspection, no signs of rust or fraying
driver door wiring, visual inspection, no signs of rust or fraying
ECU visual inspection and wiring, no signs of rust of fraying, was bone dry when I opened it up
Cluster wiring connections, they were not loose, no signs of damage or faulty connection
From what I have gathered off the internet, the possible culprits could be:
Driver door master window switch
Driver door latch/lock module/assembly, have read the forums about the micro switch failing and having to be replaced/ have a new one soldered in
and the wiring between any of these components
My goal with this post is to maybe find someone whos had this exact same problem and maybe can point me in what direction to go first, as well as maybe a fresh set of eyes for this problem. Please let me know if you have any more questions or need more specifics or pictures. This is my first real post on a forum so I apologize if this is in the wrong spot or something along those lines. Thank you for your time and assistance.