Thursday, March 5, 2015

INTERMITTENT IMPLAUSIBLE


VW POLO 9N HIGHLINE


The VW Polo comes in three flavours viz. the 9N1, 9N2 and the 9N3, dating from 2002-2009.  The Skoda Fabia and the Seat Ibiza/Cordoba share many of the 9N trates but omit Address 25 since all their onboard control module functions are not identical. In the case of the VW Polo, it shares the coding in Address 17 with Address 25 because they are linked, but this applies morso to the 9N3. However, the easiest way to recognised the 9N and its clones, are by the 6Q0, 6Q1, 6L0, 6N0 and 6R0 modules which are also populated in the Polo 6N range. The interesting thing is that even though some module are the same in both its hardware and software, they have different codings specified. It is understandable, since the coding value is subject to the collective components fitted because the coding is a sum of the binary value applicable to the individual components. This can be seen in the three scans below. Be that as it may, module coding seems to be a huge problem with most vehicle owners who do their own repairs, however I have also seen qualified mechanicians struggle for days to get a car back to its readiness state. The status chart below is what every VAG driver / owner desires from their vehicle, but  is often totally elusive.

01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
17-Instruments -- Status: Status: OK 0000
19-CAN Gateway -- Status: Status: OK 0000
25-Immobilizer -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
56-Radio -- Status: OK 0000

Readiness: 0 0 0 0 0  / Gata de funcþie: 0 0 0 0 0 / Tests passés: 0 0 0 0 0

What I have found, is that when a component that contributes to the module coding value malfunctions, the scan reads "1 Fault Found: 01044 - Control Module Incorrectly Coded" but if the malfunctioning component is first repaired or replaced, and the fault is cleared, the  01044 code does not return since the checksum of the module is once again correct. Many vehicles owners see this 01044 code and start changing module codes, normally just to see what happens. But, and a big but at that, before I continue, I need to stress that it's imperative to print out a scan of the faults and the module codings before any repairs are attempted, so that, if there is a problem, you can always revert back to the original coding. Failure to so could incapacitate your car until it can be correctly re-coded which could be both time consuming and expensive. Implausible  and Intermittent problems on VAG cars are rife or rather intermittent and implausible   problems on all cars are rife ever since control modules were introduced. The main reason for this is bad, poor or intermittent electrical contact, especially  considering the vast increased in the number of multi-pin plugs and sockets and edge connectors. Because vehicles move,  the  forces on the electrical connections constantly changes and that's besides the expansions caused by heat and the contractions caused by cold, and the corrosive effect of the weather on vehicles. Hence intermittent problems in all languages abound. What follows is just a sampling of the intermittent and implausible error codes we could encounter.

01314 - Engine Control Module
013 - Check DTC Memory - Intermittent

00816 - Sensor für Lenkhilfe (G250)
30-00 - Unterbrechung / Kurzschluß nach Plus

00716 - Air recirculation Flap Positioning Motor (V113)
000 -  -  - Intermittent

01336 - Bus de données Groupe Confort
80-00 - en mode fil unique

004506 - Fuel Pressure Sensor (G247)
P119A - 000 - Malfunction - Intermittent - MIL ON

01596 - Servomoteur de volet d´air frais/air recyclé (V154)
30-10 - Rupture/court-circuit au pôle + - Intermittent

01336 - Data Bus for Comfort System
80-10 - Single-Wire Operation - Intermittent

01271 - Stellmotor für Temperaturklappe (V68)
000 - - - Sporadisch

00588 - Airbag Igniter; Driver Side (N95)
32-10 - Resistance too High - Intermittent

00778 - Steering Angle Sensor (G85)
49-10 - No Communications - Intermittent

00706 - Relais de ventilateur de radiateur V7 et V35 -vitesse 2 (J513)
009 - Rupture/court-circuit à la masse - Intermittent

00896 - Closing unit tailgate (F256)
27-10 - Implausible Signal - Intermittent ----------

00576 - Klemme 15
002 - unterer Grenzwert unterschritten - Sporadisch

01312 - Powertrain Data Bus
37-10 - Faulty - Intermittent

00-Senzor unghi volan -- Status: OK 0000
01-Motor -- Status: Malfuncþie 0010
03-ABS frâne -- Status: OK 0000
08-Clima automatã -- Status: OK 0000
09-Electronica centralã -- Status: Malfuncþie 0010
15-Airbaguri -- Status: OK 0000
16-Electronicã volan -- Status: OK 0000
17-Instrumente bord -- Status: OK 0000
19-Poarta CAN  -- Status: Malfuncþie 0010
25-Blocare pornire -- Status: OK 0000
42-Uºa electr. ºofer -- Status: OK 0000
44-Asistenþã direcþie -- Status: OK 0000
46-Confort -- Status: Malfuncþie 0010
52-Uºa electr.pasager -- Status: Malfuncþie 0010
56-Radio -- Status: OK 0000
69-Tractare -- Status: Neautorizat 0001
76-Asistenþã parcare -- Status: OK 0000
7D-Încãlz. Aux. -- Status: Malfuncþie 0010

However,  we all desire the following messages from our cars:-  Aucun code défaut trouvé. No fault code found. Kein(e) Fehlercode(s) gefunden. Nu a gãsit coduri. Betriebsnr.: WSC 00000 / No. Atelier: 00000 WSC / Shop #: WSC 00000. The wiring harness of all cars are made with flexible multicore wire with terminal connectors and clip-lock plugs to facilitate connection durability when driving on bumpy roads and uneven surfaces but it seems that shaking, vibration, heat, shafting and corrosion are responsible for the above errors which would probably not resulted if there were not as many interconnected sub harnesses, and multi-pin electrical connections.

SCANS

Chassis Type: 9N1 - VW Polo
Scan: 01,02,03,08,09,15,17,19,37,44,46,56,69

Address 01 -------------------------------------------------------
Controller: 032 906 032 E
Component: ME7.5.10 *2503
Coding: 00071

Address 03 -------------------------------------------------------
Controller: 6Q0 907 379 AF
Component: ABS 8.0 front H03 0002
Coding: 0002175

Address 08 -------------------------------------------------------
Controller: 6Q0 820 045
Component: Klimaanlage X0840

Address 09 -------------------------------------------------------
Controller: 6Q0 937 049 D
Component: À0_0 BN-SG. 1S34
Coding: 25742

Address 15: ------------------------------------------------------
Airbags
Controller: 6Q0 909 605 AE
Component: 0H AIRBAG VW5 0C 0010
Coding: 12360

Address 17 -------------------------------------------------------
Controller: 6Q0 920 823 B
Component: KOMBI+WEGFAHRSP VDO V02
Coding: 00141

Address 19 -------------------------------------------------------
Controller: 6N0 909 901
Component: 0000 GATEWAY CAN 1S34
Coding: 00014

Address 44 -------------------------------------------------------
Controller: 6Q0 423 156 AB
Component: LenkhilfeTRW V270
Coding: 10140

Address 46 -------------------------------------------------------
Controller: 6Q0 959 433 E
Component: 67 Komfortgerát 0002
Coding: 00018

Address 56 -------------------------------------------------------
Controller: 6Q0 035 186 A
Component: Radio FF6 0001
Coding: 00401

End -------------------------------------------------------


Fahrzeugtyp: 9N - VW Polo
Scan: 01 02 03 08 09 15 17 19 25 37 44 45 46 56 76

Adresse 01: -------------------------------------------------------
   Motor
   Teilenummer: 03D 906 023
   Bauteil: SIMOS91 1.2l 2V     5415
   Revision: --H04---    Seriennummer: VWZ5Z0G8041219
   Codierung: 0000071
   Betriebsnr.: WSC 00810 219 84798
 
Adresse 03: -------------------------------------------------------
   Bremsen  
   Teilenummer SW: 6Q0 907 379 AF    HW: 6Q0 907 379 AF
   Bauteil: ABS 8.0 front   H05 0002
   Revision: 00000000    Seriennummer: 00000000000000
   Codierung: 0002082
   Betriebsnr.: WSC 00788 785 00200
 
Adresse 08: -------------------------------------------------------
   Klima/Heizung  
   Teilenummer: 6Q0 820 045
   Bauteil: Klimaanlage        X0850
 
Adresse 09: -------------------------------------------------------
   Bordnetz        
   Teilenummer: 6Q1 937 049 F
   Bauteil: 0009 BN-SG.         2S36
   Codierung: 25742
   Betriebsnr.: WSC 00788
   
Adresse 15:  -------------------------------------------------------
   Airbag        
   Teilenummer: 1C0 909 605 K
   Bauteil: 19 AIRBAG VW51 0P   0010
   Codierung: 12601
   Betriebsnr.: WSC 00788
   
Adresse 17: -------------------------------------------------------
   Kombiinstrument    
   Teilenummer: 6Q0 920 804
   Bauteil: KOMBIINSTRUMENT AGD V04
   Codierung: 01131
   Betriebsnr.: WSC 00000
   
Adresse 19: -------------------------------------------------------
   CAN-Gateway      
   Teilenummer: 6N0 909 901
   Bauteil: 01K1 GATEWAY CAN    2S36
   Codierung: 00014
   Betriebsnr.: WSC 00788
   
Adresse 25: -------------------------------------------------------
   Wegfahrsperre  
   Teilenummer: 6Q0 920 804
   Bauteil: IMMOBILIZER     AGD V04
   Codierung: 01131
   Betriebsnr.: WSC 00000
   
Adresse 44: -------------------------------------------------------
   Lenkhilfe    
   Teilenummer: 6Q0 423 156 AB
   Bauteil: LenkhilfeTRW        V270
   Codierung: 10140
   Betriebsnr.: WSC 00788
   
Adresse 46: -------------------------------------------------------
   Komfortsystem    
   Teilenummer: 6Q0 959 433 E
   Bauteil: 3F Komfortgerát     0002
   Codierung: 00019
   Betriebsnr.: WSC 00788
   
Adresse 56: -------------------------------------------------------
   Radio      
   Teilenummer SW: 6Q0 035 152 G    HW: 6Q0 035 152 G
   Bauteil: Radio DE2           0007
   Revision: 00005000    Seriennummer: VWZ4Z4G3272350
   Codierung: 0020200
   Betriebsnr.: WSC 00788 785 00200
   
Ende -------------------------------------------------------

Type chassis: VW Polo 9N
Scanner: 01 02 03 08 09 15 17 19 37 44 45 46 56 76

Adresse 01: -------------------------------------------------------
Moteur
No. pièce: 038 906 019 NC
Pièce: 1,9l R4 EDC 0000SG 6138
Codage: 00002

Adresse 03: -------------------------------------------------------
Freins ABS
No. pièce Log: 6Q0 907 379 AF Mat: 6Q0 907 379 AF
Pièce: ABS 8.0 front H05 0002
Révision: 00000000 No. de série: 00000000000000
Codage: 0002193

Adresse 08: -------------------------------------------------------
Climatronic
No. pièce: 6Q0 907 044 E
Pièce: CLIMAtronic PQ24 3805

Adresse 09: -------------------------------------------------------
Centrale Elec.
No. pièce: 6Q1 937 049 F
Pièce: 0009 BN-SG. 2S36
Codage: 09870

Adresse 15: -------------------------------------------------------
Airbags
No. pièce: 1C0 909 605 K
Pièce: 17 AIRBAG VW51 0N 0010
Codage: 12599

Adresse 17: -------------------------------------------------------
Instruments
No. pièce: 6Q0 920 825 H
Pièce: KOMBIINSTRUMENT VDO V06
Codage: 01141

Adresse 19: -------------------------------------------------------
Gateway CAN
No. pièce: 6N0 909 901
Pièce: 01K1 GATEWAY CAN 2S36
Codage: 00014

Adresse 44: -------------------------------------------------------
Direction assistée
No. pièce: 6R0 423 156
Pièce: LenkhilfeTRW V272
Codage: 10120

Adresse 46: -------------------------------------------------------
Module confort
No. pièce: 6Q0 959 433 E
Pièce: 5F Komfortgerát 0002
Codage: 00017

Adresse 56: -------------------------------------------------------
Radio
No. pièce Log: 6Q0 035 152 E Mat: 6Q0 035 152 E
Pièce: Radio 9NK 0004
Révision: 00001000 No. de série: VWZ4Z4H0100621
Codage: 0040400

End -------------------------------------------------------

Feel free to upload your VW, SKODA, SEAT & AUDI scans.

Saturday, February 21, 2015

01044 - CONTROL MODULE INCORRECTLY CODED


CONTROL MODULE INCORRECTLY CODED

Since 1994 auto repairs has drastically changed, so much so that most cars cannot be repaired  without a diagnostic code tester. It is therefore advantages to invest in one of the hand held free standing devices or cable interfaces that plugs into a USB port of a laptop computer running the appropriate software to do the necessary. The best software to date for Vag cars is undoubtedly VCDS from Ross Tech. Their latest version is version 14. The software is absolutely free but the interface cable comes at a cost. It is a bit pricy but its a worthwhile investment since it entitles you to free updates for life. This interface cable has a built in PAL chip which doubles-up as a dongle containing the cable activation code. Even though there are several out-band 3rd party interface cables available on the market, none of them gives you the confidence that a VCDS HEX-CAN automotive diagnostic device, that is backed by a service company ready to help with any automotive queries, gives you. Bare in mind that this software has the ability to change the behaviour of the electronic control systems built into your car which can result resulting in catastrophic effects if not performed correctly. If you lack the competence or confidence to perform these operations, or even if you are unfamiliar with or the software, I urge you to refrain from changing anything and obtain an experts advice or assistance. Write down or print out all codes and settings so that it is easy to revert back to them.
Below are just a few of the faults that have popped-up on various vag cars over the past few years. Since the codes cover all Vag cars, the code "01044 - Control Module Incorrectly Coded" has occurred several thousand times in all makes and models of Vag cars, in all languages and countries throughout the world.

01044 - CONTROL MODULE INCORRECTLY CODED


01044 - Modul de comanda: codare incorecta
        35-00 -  -

01044 - Steuergerät falsch codiert
        35-00 -  -

01044 - Módulo de control codificadas incorrectamente
        35-00 -  -

01044 - Modul za kontrol Nepravilno Kodiran
        35-00 -  -

01044 - module de commande codées correctement
        35-00 -  -

01044 - Control Module ongecodeerde
        35-00 -  -

01044 - Beheer Module Verkeerd Gekodeerde
        35-00 -  -

01044 - Upravljački modul Pogrešno Coded
        35-00 -  -

01044 - Control Module Nepareizi Coded
        35-00 -  -

01044 - 控制模塊編碼不正確
        35-00 -  -

01044 - Kòngzhì mókuài biānmǎ bù zhèngquè
        35-00 -  -

01044 - Modul de control codificate incorect
        35-00 -  -

01044 - Kontrolli Module kodifikua Gabimisht
        35-00 -  -

01044 - وحدة التحكم الأكواد بشكل غير صحيح
        35-00 -  -

01044 - Řídicí modul nesprávný kód
        35-00 -  -

01044 - Modul Kawalan Salah Dikodkan
        35-00 -  -

01044 - Kontrol Modülü hatalı Kodlu
        35-00 -  -

01044 - Control Module Felaktigt Kodad
        35-00 -  -

Genuine VCDS cable and Software from Ross Tech.

What I find most intriguing is that for most DTC codes, VW offers some sort of help by using words like "intermittent" " implausible" "short circuit" "limit exceeded", etc.. like these faults below, but the 01044 faulty code featured above offers absolutely none. However, I have included some data below that may be of some help. Should you find these codes helpful, all I ask is for you to like my site on G+1Facebook, Twitter, Pinterest, etc.

00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

01044 - Control Module Incorrectly Coded
35-00 -  -

01179 - Incorrect Key Programming
35-00 - -

01179 - Incorrect Key Programming
005 - No or Incorrect Basic Setting / Adaptation

00852 - Loudspeaker(s); Front
44-00 - Short Circuit

16795 - Secondary Air Injection System: Incorrect Flow Detected
P0411 - 35-00 -  -

01044 - Control Module Incorrectly Coded
35-00 - -

00933 - Electric Window Motor; Passenger Side (V148)
62-10 - No or Incorrect Adjustment - Intermittent

16795 - Secondary Air Injection System: Incorrect Flow Detected
P0411 - 002 - Lower Limit Exceeded

16825 - EVAP Emission Control Sys
P0441 - 35-10 - Incorrect Flow - Intermittent

00928 - Locking Module for Central Locking: Front Driver Side (F220)
27-00 - Implausible Signal

VW 9N CODES FOR:
CONTROL MODULE INCORRECTLY CODED

If  one of the following controllers is fitted in your car, try each of these codes individually  and you are guaranteed to solve your " Control Module incorrectly coded" problem, providing you have just changes the coding of one module or replaced only one module.  I need to stress as I have in a previous blog that every Control module that is fitted in your car has a prefered coding which is subject to the equipment it supervises. As such, its coding is stored as an onboard binary number, which in essence is the binary sum of the features for that specific module. Whereas the master ECU / Ctrl Head Dash  also stores an onboard binary number which in essence is the binary sum of all the Control Module's coding fitted in the car. This binary sum is called the checksum and any incorrectly coded  module will result in an erroneous checksum. If this is the case, the erroneous checksum is compared to a reference checksum also stored in the ECU module and any discrepancy could incapacitate your Volkswagen completely or present you with some peculiarities and error codes to match. Like the notorious 01044 control module incorrectly coded error. Checksum verification was adopted by BOSCH Motronic ECUs to validate its EPROM's stored data. So, it is wise not to change the coding or replace any control modules in your VW AUDI, SKODA or SEAT unless you are au fait with binary and hexadecimal number systems.

Address 09: Cent. Elect. [21343 login]
Component: 0009 BN-SG. 2S36

Controller: 6Q1 937 049 F
Coding: = 09870 / 09390 / 08332 / 25742 / 26030 /
26254 / 00004 / 09358 / 16396 / 08588 / 08204 /
00004 / 09646 / 24716 / 25743 / 24588 / 17422 /

Controller: 6Q1 937 049 D
Coding: = 00140 / 16524 / 09406 / 17422 / 25610 /
25614 / 25774 / 09358 / 25646 / 00012 / 01166 /
25774 / 25742 / 09870 / 09390 / 09646 /

Controller: 6Q1 937 049 C
Coding: = 09358 / 09390 / 00140 / 16396 / 25742 /
00012 / 25742 / 26046 / 25614 /

Controller: 6Q1 937 049 B
Coding: = 25754 / 09374 / 00140 / 17594 / 25758 /

Controller: 6Q1 937 049
Coding: = 00141 / 09234 / 09870 / 09362 / 09358 / 09394 / 09646 /

Address 09:  Cent. Elect.  [21343 login]
Component: 0000 BN-SG. 2S36
Address 09: Controller: 6Q1 937 049 F Coding: 09358
Address 09: Controller: 6Q1 937 049 F Coding: 25742
Address 09: Controller: 6Q1 937 049 F Coding: 25743

Address 09:  Cent. Elect.  [21343 login]
Component:  000B BN-SG. 2S36
Address 09: Controller: 6Q1 937 049 F Coding: 08588
Address 09: Controller: 6Q1 937 049 F Coding: 16524
Address 09: Controller: 6Q1 937 049 F Coding: 24716

NB! More component codes in the next blog ...

INSTRUMENT CLUSTER / IMMOBILIZER / KOMBI
6Q0 920 825

Component: KOMBIINSTRUMENT VDO V06
Address 17: Instruments Controller: 6Q0 920 825 E Coding: 01144

Component:  INSTRUMENT CLUSTER VDO V07
Address 17: Instruments Controller: 6Q0 920 825 E Coding: 01144

Component: KOMBIINSTRUMENT AGD V05
Address 17: Instruments Controller: 6Q0 920 825 F Coding: 01132

Component: KOMBIINSTRUMENT AGD V02
Address 17: Instruments Controller: 6Q0 920 825 F Coding: 01132

Component: KOMBIINSTRUMENT AGD V04
Address 17: Instruments Controller: 6Q0 920 825 F Coding: 01132

Component:  KOMBIINSTRUMENT VDO V06
Address 17: Instruments Controller: 6Q0 920 825 F Coding: 01132

Component: KOMBIINSTRUMENT VDO V03
Address 17: Instruments Controller: 6Q0 920 825 G Coding: 01132

Component: KOMBIINSTRUMENT VDO V06
Address 17: Instruments Controller: 6Q0 920 825 G Coding: 01132

COMPONENT KOMBIINSTRUMENT VDO V06
Address 17: Instruments Controller: 6Q0 920 825 H Coding: 01141

Component: KOMBIINSTRUMENT VDO V06
Address 17:  Instruments Controller: 6Q0 920 825 J Coding: 01142

Component: KOMBIINSTRUMENT VDO V05
Address 17:  Instruments Controller: 6Q0 920 825 K Coding: 01148

Component:  KOMBIINSTRUMENT VDO V02
Address 17:  Instruments Controller: 6Q0 920 825 L Coding: 01148

CENTRAL CONVENIENCE

Address 46:
Controller:Central Conv.

06 Komfortgerát 0002 6Q0 959 433 C Coding: 00067
07 Komfortgerát 0002 6Q0 959 433 C Coding: 00259

63 Komfortgerát 0002 6Q0 959 433 E Coding: 00016
3  Komfortgerát 0002 6Q0 959 433 E Coding: 00016
5F Komfortgerát 0002 6Q0 959 433 E Coding: 00017
   Komfortgerát 0002 6Q0 959 433 E Coding: 00018
63 Komfortgerát 0002 6Q0 959 433 E Coding: 00016
64 Komfortgerát 0002 6Q0 959 433 E Coding: 00019
65 Komfortgerát 0002 6Q0 959 433 E Coding: 00018
67 Komfortgerát 0002 6Q0 959 433 E Coding: 00018
3F Komfortgerát 0002 6Q0 959 433 E Coding: 00018
3F Komfortgerát 0002 6Q0 959 433 E Coding: 00019
2F Komfortgerát 0002 6Q0 959 433 E Coding: 00064
4y Komfortgerát 0002 6Q0 959 433 E Coding: 00065
4z Komfortgerát 0002 6Q0 959 433 E Coding: 00065
6K Komfortgerát 0002 6Q0 959 433 E Coding: 00065
4U Komfortgerát 0002 6Q0 959 433 E Coding: 00066
4M Komfortgerát 0002 6Q0 959 433 E Coding: 00064
31 Komfortgerát 0002 6Q0 959 433 E Coding: 00067
4T Komfortgerát 0002 6Q0 959 433 E Coding: 00258

   Komfortgerát 0002 6Q0 959 433 F Coding: 00018
   Komfortgerát 0002 6Q0 959 433 Coding: 00021

J2 Komfortgerát 0002 6Q0 959 433 G Coding: 00064
20 Komfortgerát 0002 6Q0 959 433 G Coding: 00065
41 Komfortgerát 0002 6Q0 959 433 G Coding: 00017

1N Komfortgerát 0002 6Q0 959 433 H Coding: 00018
2Y Komfortgerát 0002 6Q0 959 433 H Coding: 00018
1N Komfortgerát 0002 6Q0 959 433 H Coding: 00019  
1R Komfortgerát 0002 6Q0 959 433 H Coding: 00067
0H Komfortgerát 0002 6Q0 959 433 H Coding: 00067


Tuesday, December 23, 2014

CONTROL ARM RUBBERS

VW POLO CONTROL ARM & TIE-RODS

A couple of weeks ago to my surprise,  I discovered that my car's front tyres were running  smooth on the inside.  It was that bad that I needed to replace them but somehow I never noticed until from a distance, I saw something white stuck to the right side front tyres. I was thinking it may be a sticky sweet wrapper that got stuck to the thread, so I went to remove it. That’s when I saw it was a patch of shining wire protruding through the rubber. I was dismayed. The outer edge up to the middle of the tyre had perfect thread, at least 4mm or more but the inside was bald as an egg. 


My VW Polo getting the full treatment.

Thats where the control arm rubbers sits, 

There was no way I was going to fit brand new tyres and allow the same to happen to them. I suspected that the alignment went awry so I drove my car in that condition to determine whether I was right or wrong. I released the steering on a straight road a few times and every time the car veered to the left, towards the pavement. Convinced that it was alignment, I fitted my spare wheel and took my VW Polo Highline for wheel alignment to get it sorted before replacing the tyres.

New VW control arm rubbers / cleaned-up VW control arms

Busted rubber boots on both and left tie-rod ends, due for replacement.

 After waiting for more than an hour at the wheel alignment centre, it was eventually my turn to get service. My car was hoisted about hip high on the lift. The technicians then jacked-up the front wheels placed metal pad of sorts under each of the front wheels which was part of the wheel alignment sensor equipment that they later fitted to all four wheels. They then centred the steering wheel, locked it in place with a mechanical device and fired up the diagnostic computer/programme to check my car's wheel alignment. A good 15 minutes later they discovered that their version of the diagnostic software did not have the settings for a VW Polo 2.0 litre Highline. In fact there wasn't even a 2.0 litre Polo category listed.

Front and back view of new tie-rod ends.

There is absolutely no difference between the original ans pirate part other than the VW logo

The technician scrolled through the entire list a couple of times before he gave up and told me that they are stuck without the correct setting and therefore cannot do the alignment. I asked, what about trying the software for one of the other VW Polo models. Considering all the Polo's are the same shape and size and that it’s only the engine capacity that vary, perhaps it may work.  So he tried the 1.8 litre setting which showed my Polo's alignment was perfect and that there was no error. He then tried the 1.6 and the 1.9TDi software, both with the same results -no problem. I protested “How can that be? Look at my front tyres! Now that the car's tyres were eye-level the left tyre was almost just as bad as the right one. The technicians agreed that there is a problem and started speculating that if both my swing arm rubbers were uniformly perished the alignment would  technically still be in but the car would veer off the road and the tyres would run bald on either the inner or outer edge. They lifted the car higher and pushed a tyre lever into the control arm rubbers and convincingly said the one side is definitely broken.  Thank you very much and off I went.


Left image shows left Control arm Rubber, Right image shows right side.

Left and Right Control Arm Rubbers

Back at the VW service agents, 2 x control arm rubbers please. Yes, we have stock, R1200 (+/-$120) please. What! For two pieces of rubber? But since I needed it, I paid. Back home I jacked-up the car, placed it on car stands and stripped the front suspension until I removed said rubbers. By the way, I found the boots on tie-rod ends torn so back to the agents I went. "Sorry out of stock, expecting stock to arrive in 40 days". This was unacceptable so off to the local motor spares I went in search of tie-rod ends. I found them sold together with the control arm rubbers at R180 each, tie-rod ends R120 each. Everything together cost me R600 ($60), exactly half of what I already spent on rubbers alone. So after I fitted them to my Polo, I returned the Control arm rubbers to the VW agents for a full refund.  Amazingly the car now drives normal, no veering to the left or right and the alignment centre still says my alignment is normal, even though they or none of the other service centres they phoned have the software alignment settings for my 2.0L Polo highline. I now realise that she's an oddball.


Tuesday, October 21, 2014

EPC DEMYSTIFIED CONTINUED 2


Continued from EPC DEMYSTIFIED CONTINUED 1.


  ...  I only became aware of this when my EPC light went on due to the knock sensor. See picture blog.  More...


 PART 3


BREAKING THE CODE

What needs to be mentioned as a basis of understanding, is that OBD (on-Board Diagnostics) was introduced in the 70's along with CDI (capacitive discharge ignition systems) as DIY kits. Few cars had fuel injectors, points and coils were fast being taken over by electronic modules. During this time some standards were introduced but they were not very well defined and as such manufacturers developed their own and applied their specific systems and developed their own code descriptions which later became known as OBD1. This was considered undesirable and counterproductive since none franchised service, and general mechanical repair centers had to purchase different scan tools, interface cables and connectors, skills and manuals for each make and model of car they specialized in. This resulted in vehicle diagnostics becoming unwieldy expensive. In February of 1986, Robert Bosch founder of Bosch, introduced the CAN (Controller Area Network) serial bus system to  the Society of Automotive  Engineers (SAE) in motor town of Detroit.

This influenced the  Society of Automotive  Engineers (SAE) who subsequently drafted a list of standards and practices that aught to be implemented by all automobile  manufacturers and recommended them to the Environmental Protection Agency (EPA). The EPA weighed-up these standards and recommendations, acknowledged their benefits, and adopted them. The standards criteria included a precisely defined diagnostic connector for each auto manufacturer, a standard scan tool and a common electrical communications protocol and a common data format, and the ability to monitor other
vehicle parameters. Lastly that the standard scan tool should interface with vehicles of all manufacturer. It also included mandatory definitions and descriptions for certain emission control system  defects which was labeled the ‘P0’ Codes. Manufacturers were allowed to generate and use their own ‘manufacturer specific code descriptions’ known as ‘P1’ Codes. This collaboration of standards became known as OBDII, (OBD2) and was adopted for implementation by January of 1996. Two types of scanner codes, namely manufacturers codes like VAG codes and SEA Codes are now the standard practice.

OBD-II  

As mentioned above, Powertrain Control Module (PCM) error codes are assigned the prefix P and pertain to the, Engine management, Transmission management, Fuel Pump and Gasoline Management, Automatic Transmission – Hydraulic Control, Emission control system, evaporative emission purge control (HVAC), Auxiliary module management and other some 0n-board Hybrid application.  For example P1340  suggests that the Powertrain triggered a DTC and describes it as an "Crankshaft-/Camshaft Position Sensor Signals Out of Sequence"

From the above example it would thus be easy to interpret the DTC below relating to EPC (Electronic Power Control)

DTC (VAG)   DTC (SAE)  Society of Automotive  Engineers

16504 P0120 Throttle Position Sensor A - Circuit Malfunction
16505 P0121 Throttle Position Sensor A - Circuit - Performance Problem - Out of Range
16506 P0122 Throttle Position Sensor A Circuit - Low Voltage Input
16507 P0123 Throttle Position Sensor A Circuit - High Voltage Input
16894 P0510 Throttle Position Sensor - Closed Switch- idle micro-switches -F60 malfunctioning
17951 P1543 Throttle Actuation Potentiometer - Signal too Low
17952 P1544 Throttle Actuation Potentiometer - Signal too High
17913 P1505 Throttle idle micro-switches -F60 not/short-circuit opens
17914 P1506 Throttle idle micro-switches - Switch Does Not Open/Short to Ground
17988 P1580 Throttle Actuator (B1) Fault - May be caused by low battery if found with 16487 (P0103)

18038 P1630 Accelerator Pedal Position -G79 signal too small  (low)
18039 P1631 Accelerator Pedal Position -G79 signal too largely (high)
18040 P1632 Accelerator Pedal Position -G79 supply voltage malfunction
18041 P1633 Accelerator Pedal Position -G185 signal too small
18042 P1634 Accelerator Pedal Position -G185 signal too largely
18047 P1639 Accelerator Pedal Position 1+2 Range/Performance -G79 and -G185 implausible signal
18048 P1640 Internal Controller Module defective (EEPROM) Error

EPC Circuit.

The EPC  circuit consists of a number of disparate components that control and supervise, regulate and determine the throttle valve position at all times. They include;

1) the accelerator pedal position sender (TP sensor G69)
2) the accelerator pedal position sender -2, (G185)
3) Black 6-pin plug with 6-pin with Gold plated contacts

NB! The above three components are part of the accelerator pedal.

4) the throttle valve control module (unit),
5) the K132 EPC fault lamp, (electronic throttle control fault indicator)
6) the engine control module (unit).

Firstly we going to do a test on components 1, 2 and 3 above. To do this test, you need a Fluke multimeter or similar for a voltage and continuity / resistance test. Unplug the 6-pin plug from the accelerator pedal and switch on the ignition. Connect the multimeter and check for a 4.5 volt reading between;-

pin 1 and ground, then between pin 1 and pin 5
Pin 2 and ground, then between pin 2 and 3.
If tests prove to be "OK", switch ignition off.
Do additional checks for short circuits between one another and ground and if this checks "OK",

Locate the ECU, normally inside cowl. Disconnect the ECU from its socket, identify pins 34 & 34, 35 & 36, and 72 & 73 on the socket. Disconnect the 6-pin plug from the accelerator pedal once again and check for continuity between this plug and the ECU socket. There should be continuity between pins:-

1 of the 6-pin plug and pin 72 of the ECU socket.
2 of the 6-pin plug and pin 73 of the ECU socket.
3 of the 6-pin plug and pin 36 of the ECU socket.
4 of the 6-pin plug and pin 35 of the ECU socket.
5 of the 6-pin plug and pin 33 of the ECU socket.
6 of the 6-pin plug and pin 34 of the ECU socket.

Any resistance above 1.5ohms should be investigated for corrosion. This often causes the engine to surge (idle unevenly or rather breaths) However, if this test proves "OK" and no wiring malfunction is detected, replace G69 and G185 (single unit) on the accelerator pedal. NB! these components are non adjustable and needs to be replaced as a whole.

When the ignition is turned on, the ECU checks all EPC components necessary for the proper  functioning of the Electronic Power Control. If a malfunction is detected in the EPC (Electronic Power Control) system whilst the engine is running, the ECM will simultaneously activate the EPC (Electronic Power Control) warning light and make an entry of this malfunction in  the ECU (electronic Control unit) DTC (Diagnostic Trouble Codes non-volatile memory.  By a process of eliminate the EPC fault can be fixed.

The list below categorises VW and Audi manufacturer predetermined data groups which varies depending on the vehicle, year, engine, engine code and management system on board.

Group Number / Group Category

1–9     General engine activity data
10–19 Ignition data
20–29 Knock control data
30–39 02 sensor control system data
40–49 Three-way CAT data
50–59 Engine speed control data
60–69 Throttle drive data
70–79 Emissions reduction data
80–89 Special function data
90–97 Power increase data
98–100 Compatibility data
101–109 Fuel Ignition data
110–119 Boost pressure control data
120–129 Control unit communication data
130–150 Special info data

Based on the data from the above table EPC problems are associated with group 60-69. However, on Expert Systems Diagnostics Group 60, holds the EPC Adaptation data, group 61 holds EPC-system 1 data and group 62 holds the EPC system 2 data. Group 66 holds the speed-o-cruise data.

NB! If you found this information useful, please link to this page.