VW 9N HVAC

VW 9N HVAC PROBLEMS

There are hundreds if not thousands of VW owners who have had HVAC (Heating, Ventilation and Air Conditioner) problems, some are still having HVAC problems on a daily basis and those who haven't had HVAC trouble as yet, is sure to encounter them rather sooner than later.  These three functions are often combined into a single system in most modern vehicles and VW Polo 9N owners seemed to be  more affected by a failing HVAC system  than other VW owners in general.   If you've noticed your Polo 9N's temperature gauge misbehaving — randomly going up and down — but not reaching the required  90 deg, then you can expect your aircon/heater to go faulty. The problem with the HVAC is the poor quality of the two flat motors that control the flaps. Since the 9N Polo 2002-2009 are now ageing, thus out of warranty, we can expect more HVAC problems. Though in my opinion 9N HVAC problems should still be repaired under warranty, considering a car fan / air conditioner is only used for short burst at a time, a few times per day for roughly three month a year, so its collective millage is a far cry from the ceiling mounted fan at home that in some cases last a lifetime. Those fan motors just go on forever. But these motors don't spin constantly they only do while they open or closing a flap. Something like a throttle control flap motor.

Be that as it may, the need for a working climatic control system is upon us. For those in Europe or living above the tropic of cancer, it is almost imperative that your HVAC works because Winters can get quite cold up there. However, what's worse than getting cold? You guessed it, it's getting hot! In the Southern Hemisphere during mid summer, the inside of a car can reach or even exceed 50 degrees Celcius. That's the kind of heat very few people can handle without a HVAC. 

VW Polo 9N Air Heater Vent Flap Positioning Motor Square plug /
oval plug 6Q0 907 511 and oval plug 6Q0 907 511-A

HVAC problem are not limited to the temperature 'Flap motor (P/N 6Q0 907 511) and 'Recirculation Motor (P/N 6Q0 907 511C). There is also a fairly troublesome sensor (G65) attached to the  high pressure air hose, on the right side of the engine. The  Klimaanlage X0830 /X0840 / X0850 / Control Module 6Q0 820 045 is also notorious for giving up the ghost. When the Control Module goes faulty or goes offline, a VCDS scan often present an 'Internal Control Module Memory Error'. But before replacing the Control Module, check the wiring to and from the Control Module including the Voltage Supply and make certain there is a solid ground connection. The reason for the 'Internal Control Module Memory Error' is because the Gateway control module stored a checksum for all the on-board modules and when a module goes offline, the parity bit will be different from the stored one and presents itself as  'Internal Control Module Memory Error'. 

Air flow flap positioning motor V71

The problem with this, is that vehicle owners are temped to change the coding of one or more of their control modules just to see what happens. Very importantly, before we continue, I need to stress if you have an urge to do so, make certain that you have a full printout of all the coding values of all the control modules before changing anything. Failure to do so could render your VW Polo unusable because there is no guide or manual that specifically tells you which bit in the coding  does what. Trial and error can brick your car permanently. So take care!

The average HVAC fault can range from a 1 line fault to as many lines in the list below. Normally you would encounter 2 faults, 3 faults  or 4 faults, 5 or 6 faults, 7 or 8 faults at a time, all related to the same system.  When the HVAC goes faulty, it is common to have hot air blowing that cannot be turned down even though the temp control is set to cold (blue). It is just as common to get no warm air at all, even on maximum hot (red). The cause of the problem is the two motorized flaps in the heater system because both motors (V68) and (V154) are somewhat unreliable and tend to jam intermittently. The one motorized flap controls the heat and the other controls the amount fresh air entering the vents. The only way to fix this problem, is to replace both motors but doing so is a huge job because getting to the heater mechanism requires you to remove the dashboard, steering wheel, the airbags and of course the battery before commencing. It is better left for the VW agent but let me remind you that this repair doesn't come cheap.

Address 08: Auto HVAC        Labels: 6Q0-820-045.lbl
   Part No: 6Q0 820 045
   Component: Klimaanlage        X0830 / X0840  / X0850

00705 - Relay for Coolant Fan; Stage 1 (J279)
            31-00 - Open or Short to Ground
00819 - High Pressure Sensor (G65)
            07-00 - Signal too Low
00819 - High Pressure Sensor (G65)
            31-10 - Open or Short to Ground - Intermittent
01271 - Positioning Motor for Temperature Flap (V68)
            41-10 - Blocked or No Voltage - Intermittent
01271 - Positioning Motor for Temperature Flap (V68)
            30-10 - Open or Short to B+ - Intermittent
01271 - Positioning Motor for Temperature Flap (V68)
            29-10 - Short to Ground - Intermittent
01271 - Positioning Motor for Temperature Flap (V68)
            28-10 - Short to Plus - Intermittent
01299 - Diagnostic Interface for Data Bus (J533)
            79-00 - Please Check Fault Codes
01317 - Control unit in dash-J285
            79-00 - read data from memory
01596 - Motor for Outside/Recirculated Air Flap (V154)
            41-10 - Blocked or No Voltage - Intermittent
01596 - Motor for Outside/Recirculated Air Flap (V154)
            41-00 - Blocked or No Voltage
01596 - Motor for Outside/Recirculated Air Flap (V154)
            30-10 - Open or Short to Plus - Intermittent
01596 - Motor for Outside/Recirculated Air Flap (V154)
            30-00 - Open or Short to Plus
01596 - Motor for Outside/Recirculated Air Flap (V154)
            29-10 - Short to Ground - Intermittent
01596 - Motor for Outside/Recirculated Air Flap (V154)
            28-10 - Short to Plus - Intermittent
65535 - Internal Control Module Memory Error
            00-00 - -

There are also a few other motors that may go faulty amongst them are V70  (Central flap control motor) ,V71 ( Fresh/recirculating air flap motor) , V107 (Defroster flap control motor) and lastly V2 the fresh air blower motor.

VW CADDY PROBLEM

VW CADDY PROBLEM

My business partner recently bought a VW Caddy 1.6L for our Security / CCTV installation business, not the one with the passenger seats inside in the back but the commercial panel van type. It came with the rear swing door lock removed and permanently bolted shut with the rear windows sprayed black. The windscreen mounted rear view mirror was also missing, since it served no purpose because of the black rear windows. Other than that, the vehicle was in pretty good nick, oh! and except for the fact that the black door handles were faded towards white or rather, had faded areas where the vehicle user's fingers rubbed through the coating. This is first for me. I would have though Volkswagen would use black PVC for the actual handle than use  white PVC, then coat it black. 

Faded VW Caddy door handle.

I've always know "VW door handle" to be problematic since I have had personal experience with both my VW Golf I and VW Golf II. Many of you may relate to the instance when you pulled youe VW's door open and the handle came adrift and you had to stick you finger through the hole in the door and tug a flat metal lever to open it. Subsequently VW changed the style of the door handle or  rather it is now properly fixed to the door. However, the Caddy's door handles aren't faulty..... yet, just faded. 



Anyway, so after about 12 000 km she developed a engine mis but it was extremely intermittent and therefore difficult to pinpoint. Each mis probably lasted about 3 seconds, it just didn't last long enough to make a proper diagnosis. Unfortunately, my son went to view a VW Tiguan for purchase in another province and took my VCDS with him.  So we were flying blind and had to rely on common sense and good old mechanical experience. We speculated that it may be the spark plugs, but then again it could also have been the coil pack or perhaps not. The coil pack would make the entire vehicle shake, so speculation continued until we were alerted by a flickering  Electronic Stability Control (ESC) light. 

As can be seen, to get to the spark plugs is a bit of a mission.

We concluded that this may have  something to do with the rotation of the wheels or perhaps the ABS because if any one of the wheels slipped or shaved against a pavement, causing the ABS to loose count of the rotational wheel pulses, then an error may occur and trigger the Electronic Stability Control (ESC) light. After a day or two, the AFS light also turned on,  accompanied by the  Electronic Stability Control (ESC) light that now stayed on permanently. Suddenly the Caddy turned into a stubborn mule, it could move forward at a mule's pace yet it didn't matter how much you beat the accelerator, she would just splutter. It was time that we fix her.  But since there were two instrument panel light that came on almost simultaneously we needed to look at what was common to both circuits before we started replacing anything.  Much later we realized that they were completely unrelated and that both lights turning on simultaneously was purely coincidental. We found that the AFS light was triggered by one of the right front headlight bulbs that fused. We then solved that problem.  

View of the purple OBD-II plug and the VCDS adaptor inserted

Thus far we speculated on several things but the logical step was to eliminate the spark plugs — because plugs misfire — and thereafter perhaps the  electronic coil. Since the spark plugs are inaccessible unless the intake manifold is removed, we ended up doing just that. The four plugs were removed and we discovered they were of the wrong type, someone had already replaced them before. The ones we removed were the regular single spark type whereas the recommended spark plug for the VW Caddy is the twin spark type. After replacing all four plugs with the twin spark type, the instrument light turned off and the Volkswagen Caddy idled perfectly normal. It really wasn't worth trying to figure out which plug went to heaven because the cost of replacing them was much less than the value of time. When my son finally returned with my VCDS, I scanned the Caddy and dropped it in below per you perusal.  

Electronic Stability Control light and the AFS light

As can be seen the malfunctioning items below are highlighted which remained 'Red' on VCDS even after we completed the necessary repairs.  We then had to clear the DTC memory for the ECU to be updated because even though the repairs were done, the ECU didn't know. Thereafter their  status revered to OK and the Readiness passed, which can be view  right at the bottom!  The refrigerant pressure problem under Address 08: Auto HVAC remained but the levels are fine so I suspect an electrical problem. Talking about electrical problems, the blower fan was also faulty and didn't work on all setting, so after replacing the series resistor, the blower works just fine. I covered fan blowers in a previous blog but I just needed to add the pic below because the Caddy resistor looks somewhat different.

Chassis Type: 2K (1K0)
Scan: 01 03 08 09 15 16 17 19 25 44 56

VIN: WV1ZZZ2KZ7XXXXXXX

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: Malfunction 0010
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
56-Radio -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06A-906-033-BGU.lbl
   Part No: 06A 906 033 ES
   Component: SIMOS71 1.6l 2V     8720
   Revision: --H03---    Serial number: VWZ7Z0F7186813
   Coding: 0000071
   Shop #: WSC 35110 377 00190

4 Faults Found:
16414 - Oxygen (Lambda) Sensor B1 S1: Heating Circuit
            P0030 - 009 - Malfunction / Open Circuit
             Freeze Frame:
                    Bin. Bits: 00000100
                    Resistance: 16.38 kOhm
                    Voltage: 2.100 V
                    Load: 7.8 %

            P0301 - 006 -  - Intermittent
             Freeze Frame:
                    RPM: 3072 /min
                    Mass Air / Rev.: 403.3 mg/str
                    Temperature: 72.0°C
                    Lambda: 0.0 %
                    RPM: 2144 /min
                    Mass Air / Rev.: 92.7 mg/str
                    Temperature: 73.5°C
                    Lambda: 0.0 %

            P0201 - 009 -  - Intermittent
             Freeze Frame:
                    RPM: 640 /min
                    Mass Air / Rev.: 119.9 mg/str
                    Lambda Factor: 1.016
                    Bin. Bits: 00000000

17658 - Fuel Level too Low
            P1250 - 000 -
             Freeze Frame:

Readiness: 0110 0101
-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK70.lbl
   Part No: 1K0 907 379 P
   Component: ASR FRONT MK70      0105
   Coding: 0017106
   Shop #: WSC 35110 377

No fault code found.
-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-820-047.lbl
   Part No: 2K0 820 047 AQ
   Component: Climatic PQ35   120 0606
    Shop #: WSC 00000 000

1 Fault Found:
00229 - Refrigerant Pressure
            002 - Lower Limit Exceeded
-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels: 1K0-937-049-21-B.lbl
   Part No:  1K0 937 049 AD
   Component: Bordnetz-SG     H52 2102
   Software Coding: 008C4F010004100057000000000000000009B1065C0000
   Shop #: WSC 35110 377

1 Fault Found:
00979 - Lamp for Low Beam; Right (M31)
            010 - Open or Short to Plus
-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW52.lbl
   Part No:   6Q0 909 605 AH
   Component: 09 AIRBAG VW52  023 2400
   Coding: 0012345
   Shop #: WSC 35110 377

No fault code found.                  
--------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl
   Part No:    1K0 953 549 AN
   Component: Lenksäulenmodul 636 0070
   Coding: 0000001
   Shop #: WSC 35110 377

No fault code found.
--------------------------------------------------------------------------------
Address 17: Instruments Labels: 1K0-920-xxx-17.lbl
   Part No SW: 2K0 920 843 B HW: 2K0 920 843 B
   Component: KOMBIINSTRUMENT VDD 1612
   Revision: V0003000 Serial number: VWZ7Z0F7117651
   Coding: 0016101
   Shop #: WSC 04556  996

No fault code found.                
--------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 1K0-907-530-V2.clb
   Part No: 1K0 907 530 K
   Component: J533__Gateway   H04 0020
   Coding: 3D01034007007401
   Shop #: WSC 35110 377
                   
No fault code found.
--------------------------------------------------------------------------------
Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb
   Part No: 2K0 920 843 B
   Component: IMMO            VDD 1612
   Coding:
   Shop #: WSC 00000 000
                   
No fault code found.
-------------------------------------------------------------------------------
Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb
   Part No: 1K2 909 144 L
   Component: EPS_ZFLS Kl.140 H07 1806
   Shop #: WSC 35110 666

No fault code found.
-------------------------------------------------------------------------------
Address 56: Radio Labels: 1K0-035-1xx-56.lbl
   Part No: 1K0 035 186 T
   Component: Radio BVX 016 0023
   Coding: 0020200
   Shop #: WSC 35110 377

No fault code found.

End.
-------------------------------------------------------------------------------
-------------------------------------------------------------------------------

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010 (Suspect electrical fault since the level is correct)
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
56-Radio -- Status: OK 0000

Address 01: Engine        Labels: 06A-906-033-BGU.lbl
   Part No: 06A 906 033 ES
   Component: SIMOS71 1.6l 2V     8720
   Revision: --H03---    Serial number: VWZ7Z0F7186813
   Coding: 0000071
   Shop #: WSC 35110 377 00190

No fault code found.
Readiness: 1110 1101    (Readiness /faulty condition [above]: 0110 0101)

VOLKSWAGEN e-GOLF

IS IT TIME TO DITCH VOLKSWAGEN?

The year 2016 is fast coming to and end but will always be remembered as the year that Volkswagen AG  needed to reverse public perception over the diesel gate scandal that affected some 11 Million vehicles globally during 2015. With it's hands full with public apologies, court battles, falling share prices, Diesel vehicle recalls and general damage control caused by the negative impact to their brand after admitting  that they circumvented emissions standards; VW have been somewhat curtailed from their key business of manufacturing cars.

With the uncertainty regarding the future of diesel, especially considering that the mayors of Paris, Madrid, Athens and Mexico City pledged to ban all diesel cars by 2025. And with the ever looming legislative imperative to cut down on carbon dioxide (CO2) emissions and other harmful gases, automotive manufacturers as a whole have started to seriously invest in electric-powered-car technology. 

Volkswagen produced the Volkswagen e-Golf hatchback which is however not a purposely built electric car but rather shares the powertrain hardware of the Golf MK7 MQB (Modularer Querbaukasten) Typ 5G, but  fitted with an electric motor in place of its petrol/ diesel powered engine. The e-Golf is in direct competition with other purpose  built electric cars from  several manufacturer's vehicles, like the Renault ZOE hatchback, Hyundai Ioniq Electric, Tesla Model S hatchback, Tesla Model X SUV, BMW i3 hatchback, Nissan Leaf hatchback and the Kia Soul hatchback. Be that as it may, VW has sold more than 25 000 units worldwide since 2014. The VW e-Golf matches the competition in range, but the the battery management doesn't have an  active cooling system which seriously affects longevity. VW hasn't in anyway been innovative nor produced anything new. Their VW e-Golf doesn't offer anything more than the competition already does and certainly amounts to less bang for your buck. Apparently the Renault ZOE hatchback seems to be the pure electric vehicle that's leading the EV race in virtually all categories. 

However, VW has always been promoting “Clean Diesel” as an alternative to hybrid and electric vehicles, thus pushing their 2009–2015 Volkswagen Jetta 2.0L TDI, 2010–2015 Volkswagen Golf 2.0L TDI, 2010–2015 Audi A3 2.0L TDI, 2012–2015 Volkswagen Beetle 2.0L TDI, 2012–2015 Volkswagen Passat 2.0L TDI,  etc, globally. It has now come to light that not only has Volkswagen cheated on emission testing with the 2.0L TDI engines, but also on the 3.0L  fitted in the 2009–2015 Audi Q7 3.0L V-6 TDI, 2009–2016 Volkswagen Touareg 3.0L V-6 TDI, 2013–2016 Porsche Cayenne Diesel 3.0L V-6. 




Volkswagen had hardly settled to pay $14.7 billion and announced a buyback schedule, thinking  it was putting an end to the Dieselgate scandal when the German weekly newspaper 'Bild am Sonntag' and the 'Wall Street Journal', citing unnamed sources reporting that the California Air Resources Board (CARB) have found new Emissions-Cheat Device / emissions-lowering software on an Audi. Test results  revealed that the Audi was emitting less carbon dioxide than it did during normal use, but when the steering wheel is turned more than 15 degrees, this program would shut off, detecting that the test had completed. The Wall Street Journal alleges that Audi management specifically detailed the defeats during their meetings.




This affects all VW owners and by the looks of things, other car manufacturers have surpassed Volkswagen in several categories. Looking at comparisons in Overall, Reliability, Build Quality, Running Cost, Performance, Road Handling, Ride Quality, Ease of driving, Seat Comfort, Practicality, Car Tech, Volkswagen is either doing very badly or in some cases doesn't feature at all. Volkswagen was lying in 10th position on the top 10 selling cars globally but has subsequently been  surpassed by Tesla Motor Company, that is a new entry into the car market or rather the EV market.

Fortunately for VW, its subsidiary Audi is still in the race even though it lost 6% in sales compared to the previous year as can be seen on the "Cars Top 10" slide.  Porsche  is also in the running but there doesn't seem to be stats available as yet. Looking at the three stats sheets above, it can be clearly seen the VW lies 19th for Build Quality, 19th for Running Cost, 16th for Ride Quality but for Overall  and Reliability it doesn't even feature. What were we thinking when be bought into Volkswagen? I am seriously thinking of turning my VW Polo into an EV, then I won't have any more engine problems, especially not issues associated with that pesky EPC light and Limp mode home.

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VW AUDI SKODA SEAT

VW AUDI   SKODA  SEAT 

Can you believe it, Volkswagen  cars are produced with cookie cutters! Ok, ok that's exaggerating it a bit. I just needed to stretch this  analogy so that you can stretch your  imagination.  Volkswagen AG (VAG) has use the A04 / PQ24 platform for several of their cars during 2001 - 2015. Hence it turns out that the VW Polo 9N1, VW Polo 9N2,  VW Polo 9N3, VW Polo 9N4, the Volkswagen Fox 5Z1,Volkswagen Fox 5Z3, the Skoda Fabia 6Y2, Skoda Fabia Sedan  6Y3, Skoda Fabia Combi 6Y5, the Skoda Fabia-2 542, Skoda Fabia Combi-2  545, the Russian Skoda Fabia-2  572, the Skoda Roomster 5J7, the Audi A2 8Z0, the Seat Ibiza-3 6L1 and the Seat Cordoba 6L2 all share many similar features and electronic modules, engine components, wiring harnesses, if not the same, perhaps even identical. By just looking at the four of them, it is easy to see this, except for cosmetic changes of course. But underneath their outer apparel they are the virtually the same car using the same mechanical and electronic spares.

Volkswagen subsequently revised  their vehicle platform naming and identification system, for their ultra-compact (city cars), super-mini cars, compact cars (small family cars), mid-size cars and their full-size luxury cars to  numbers that look like PQ24, PQ25, PQ34, PQ35, etc. PL45, PL46, etc, PL62,  PL64 etc. For the uninitiated it only brings about more confusion in an already confusing time of information overload.

SUPER MINICARS

"A01" platform for the Volkswagen Polo Mk1,
"A02" platform for the Volkswagen Polo Mk2 - Classic, 
"A03" platform for the Volkswagen Polo Mk3- 6N/6KV,
"A04" platform is now known as the PQ24  -  all cars listed above,
"A05" platform is officially the PQ25 - for Audi A1, VW Polo (6R) and  SEAT Ibiza (6J). 

But for now we are interested in the meaning of platform codes like PQ24, PQ25, PQ34, PQ35, etc. PL45, PL46, etc, PL62,  PL64 and see how it affects the VW Polo range of cars with regards to spares and repair procedures.  When deconstructing the platform codes, we discovered that the  nomenclature for PQ24 is derived as follows:-

P - stands for a passenger car platform
Q - (Quer in German) stands for a transverse engine
2 - stands for the platform size or class
4 - stands for the generation
Essentially implying a passenger car platform with a transverse engine, fitted into a supermini of the fourth generation (MkIV).

Meaning, one of the cars mentioned in the heading of this blog installment, since all of them are classified as supermini cars.

Whereas the nomenclature for PL45 is derived as follows:- 

P - stands for a passenger car platform
L - (Längs in German) stands for a longitudinal engine
2 - stands for the platform size or class
5 - stands for the generation
Essentially implying passenger car platform with a longitudinal engine, fitted into a mid-size cars of the fifth generation (MkV).

Meaning a Volkswagen Passat (3B) or a Audi A4 (8D), etc.

Whereas the nomenclature for PL64 is derived as follows:
P - stands for a passenger car platform
L - (Längs in German) stands for a longitudinal engine
6 - stands for the platform size or class
4 - stands for the generation
Essentially implying passenger car platform with a longitudinal engine, fitted into a full-size luxury car of the fourth generation 

Meaning a Volkswagen Phaeton, Audi A8, or even a  Bentley Continental GT, etc.

Platform nomenclature was decided because car manufacturers are determined to get a better return on investment by using the same robotic arms and software programming on their  assembly lines / conveyer belts to assemble a host of different vehicles that look similar, with predominantly the components.  Also meaning that the space needed to stock parts are greatly reduced because instead of stocking the same part for 15 different models they have to stock just just one.

Case in point is the Joint-venture between Volkswagen and Ford Motor Company for producing the  Volkswagen Sharan (7M), SEAT Alhambra (7M), and the Ford Galaxy (7M). Volkswagen also started a Joint-venture between themselves and Daimler AG, to produce the Volkswagen LT range and the Second and third generations Mercedes-Benz Sprinter. In a sense one can just call this badge engineering, because Mazda and Ford have also have had long-term alliances, making cars until their partnership dissolved. 

EGR ERROR CODES

EGR EXHAUST GAS RECIRCULATION

Pre OBD vehicles had no need for an EGC circuit because these older cars had large noisy engines, were relatively fast, were gas guzzlers and  were emitting noxious exhaust emissions as if nobody cared about the environment. When combustion takes place inside an engine's cylinders, nitrogen and oxygen combine to form various oxides of nitrogen; which are collectively termed NOx. NOx emissions are generated as a function of high combustion temperature, so when it was discovered that these noxious gas emissions (NOx) were partly responsible for damaging the ozone layer and contributing to global warming, the EPA recommended legislation for OBD/EOBD/OBD-II systems to be fitted into all cars built after 1996 in order to monitor exhaust emissions.  

VW Engineers then came up with an EGR circuit which took different forms and configurations and were often particular to the make, model and manufacturer of the vehicle. EGR can be achieved either internally by means of valve overlap, or achieved externally by means of a  simple arrangement of pipes and a sprung loaded mechanical valve or an electronically controlled solenoid valve. Some turbo charged engines incorporate a low and high pressure exhaust Gas Recirculation system whereas some non-turbo engines only use high pressure EGR. Engines with diesel particulate filter systems tend to use a fast switching electronically actuated EGR valve, whereas a pneumatically activated EGR valve is employed by several others. Some engines used vacumm controlled EGR and some use water-cooled systems, yet all designed to supplement the traditional air/fuel ratio and spark timing circuit. 

VW 2.5 TDI AXG, AHY &  ACV engine  Pressure Converters,
EGR Valve Control Solenoid, EGR Pressure Feedback Sensor

Today virtually every vehicle manufacturers employ exhaust gas recirculation (EGR) as an emissions control sub-system in their cars, which has become an integral part of OBD-II.  The OBD-II exhaust gas recirculation system monitor is responsible for determining the serviceability of the sensors, hoses, solenoids, valves and actuators that are part of the EGR system and any problem with them would most likely trigger a binary '1' in a readiness test. Readiness tests evaluate eight on-board monitors to gauge the integrity of the engine.  Having said that, On-board diagnostic monitoring predominantly applies to systems that are most likely to cause an increase in harmful exhaust emission and during roadworthy testing these systems are specifically checked to verify compliance with EPA / government regulations.

Modern day EGR circuits essentially consists of electronic components and intelligent computer circuitry capable of recirculating a precisely controlled amount of non-combustible exhaust gas back into the intake manifold. A sort of a feed-back loop if you like. The objective is to  attain  lower combustion temperatures  and obtain optimal NOx reduction at middle and high engine loads. Restated, the greater the EGR the lower the NOx. NOx is poisonous and it is in the interest of every vehicle owner to keep their carbon footprint to a bare minimum.

The components involved in the EGR circuit are, the Mass air flow rate (MAF) sensor G70, Engine Exhaust Gas Temperature (EGT) Sensor 1 G235, Exhaust Gas Temperature (EGT) Sensor 2, Exhaust Gas Temperature (EGT) Sensor 3 G495, Exhaust Gas Temperature (EGT) Sensor 4 G648, EGR Vacuum Regulator Solenoid Valve N18 / N121, Exhaust gas Heated Oxygen Sensor (HO2S) G39, Wastegate Bypass Regulator Valve N75, Hot-film air mass meter G70, Engine  RPM sensor and the position of the EGR Potentiometer G212. EGR Cooler Switch-Over Valve N345, which are all vehicle dependent. These transducers  assists the Engine Control Module to recognizes the position of the spring loaded valve plate so that it can adjusts the actuator (electric controlled motor) that in turn controls the gas return flow so that it can  mix with a portion of  fresh air entering at the intake manifold. This lowers the internal combustion temperature and reduces the formation of oxides of nitrogen and keep it well within the legal limit.

However, when this doesn't happen, Engine performance is un-noticeably lower, causing the Glow Plug Indicator Light to flash  continuously  in the case of diesel powered vehicles and the Engine management light in the case of gasoline powered vehicles. Meanwhile the ECU will also register a DTC in its non-volatile fault memory. In the event of a EGR malfuntion which wound't normally be noticed by  the driver if it wasn't for the instrument cluster light that flashes or stays on, don't just start replacing components. First and foremost clean out any carbon buildup with Wynnes EGR 3 cleaner, then check the sensor harness and their respective connectors and check solenoids for continuity.

The likeness of the EGR valve can be compared to the throttle valve, both are butterfly plates that are electronically controlled by the ECU causing them to open and close dependent on the calculated duty cycle of the generated drive pulse. The wider the throttle opens the higher the engine will rev, likewise the wider the EGR valve opens the better the engine performs and the less NOx it produces.

EGR ERROR CODES

Error codes staring at P0400 - P0409 ranges from malfunction of N18 (EGR Valve) to low/high signals from G98 (EGR Temperature sensor) to spurious signals from G212 (potentiometer)

Error codes staring at P1400 - P1408 ranges from Electrical Malfunction, to   Short to Ground/ Positive, too low or high

Error codes  P042E &  P042F dictates that the Exhaust Gas Recirculation "A" Control valve is, Stuck Open and stuck Closed respectively.

Error codes   P045E & P045F dictates that the Exhaust Gas Recirculation "B" Control valve is, Stuck Open and stuck Closed respectively. ts fairly pevalent on VW Jetta.

Error codes P2BAB & P2BAC dictates on incorrect EGR Flow, that NOx levels have exceeded and that the EGR has been deactivated.  Its fairly prevalent on the VW Crafter.

Once your problem is solved, it is imperative that you put  your VW, Audi, Skoda or Seat  vehicle, through a drive cycle but remember the drive cycle is manufacturer specific and should be executed accordingly.

PETROL vs DIESEL vs ELECTRIC VEHICLE COMPARISON

PETROL, DIESEL, ELECTRIC VEHICLE COMPARISON

Owning a VW Polo is fairly easy but when the exorbitant costs of unforeseen repairs and regular servicing are added, it becomes really expensive. To make matters worse, with the regular petrol price hikes, maintaining that VW Polo can become a bit of a burden.  The distance traveled by the average motorist, based on "official trade figure"  is estimated at 20 000Km per annum which directly translates to about 1667km per month or 55 km per day. At the current price of petrol (R12.89 per litre), that 55km would cost you about R43.00 subject to your Polo's Km/litre average consumption and your personal driving style. Extrapolated over a period of one year would cost you a cool R15,480.00-plus per annum and over the 60 months finance period, a whopping R77,400.00.

Volkswagen  e-Golf EV Charger Connection

Suddenly a diesel powered VW Polo TDI seems more financially attractive, especially considering that its fuel consumption of 4.6 litres / 100 km is far lower than the 5.9 litres / 100km of the low end VW Polol 1.4 Trendline. If truth be told, its a saving of at least 25 percent comparatively speaking but it's really  not that cut and dried.  My hesitancy towards a Diesel Vehicle gravitates around the fact that Volkswagen as a company had 'cheated on the fuel consumption and emissions figures globally', so I'm wondering how true these stats released by Volkswagen really are. Surprisingly, independents tend not to do comparative consumption studies or rather if they do, they don't make the results public. However, my consolation is based on my wife's Mercedes Benz C250D,  that uses a sight less fuel than her previous petrol powered C230E model over the same distance. Besides, virtually every heavy duty delivery vehicle out there is diesel powered because big business would invariably choose the more economical option. 'Diesel vehicles also tend to be less troublesome than petrol powered trucks'. They may not be as fast as their petrol powered versions but they have enormous torque, far great than their petrol counterparts. Then there is always the turbo version to consider that is much faster. Be that as it may, I'm not completely convinced whether or not to go that route.

Petrol and diesel fuel consumption comparison chart

There is a third alternative that I should explored and that is an electric powered vehicle. I quite like the VW e-Golf because its completely silent. It goes up to an estimated 133km per charge which I deem sufficient for short distance city driving. Unlike other manufacturer's purpose built electric cars, the VW e-Golf is essentially a normal VW car with an electric motor sitting in place of a petrol or diesel engine, with the fuel tank space occupied by its battery pack. Several car manufacturers are currently producing a small number of electric vehicles but it's painfully obvious that their range will expand in the coming years. So it's a good idea to embrace the newer zero emissions electric technology now, rather than later, in preference of further polluting our eco-system  with carbon dioxide emissions. But these EV's are a lot more expensive than both the petrol and diesel versions and the cost of electricity for charging its lithium-ion batteries still needs to be added. There is a likelihood that government will subsidize electric cars above a certain price range. It would probably work along the lines similar to the Eskom subsidy which is available to those home owners who intend installing a heat pump in their homes. My hesitancy revolves around recharging the EV when not near the home-based power unit. Regardless,  it makes more sense to buy the electric car, rather than a petrol or diesel car? My biggest concern though, is that lithium-ion batteries are still in its infancy or rather hasn't  properly matured yet. Though, there is a battery leasing option that comes at a monthly cost which will bring the overall monthly cost to more than than of maintaining a diesel VW Polo. Somehow this EV isn't looking that great anymore. But what I need to say is that I am very impressed by the distance that the Tesla can go on a single charge, as well as the overall quality of their new battery pack.

This impressive 115-hp electric motor with 269nm of torque makes for a really enjoyable drive.

EV Fuel Cost Comparison Example

	Units	BE	Petrol	Diesel
Combined Fuel Efficiency		150Wh/km	8L/100km	6L/100km
Annual Mileage	km	120,000	20,000	20,000
Annual Fuel Requirement	Litres	0,00	1600	1200
	kWh	2,400	n/a	n/a
Energy / Electricity Prices / Unit	Litre /KW	11.75	12.98	10.69

HEATER FAN BLOWER MOTOR TANDEM RESISTOR

HEATER FAN BLOWER NOT WORKING

With Winter looming in the Northern Hemisphere and Summer looming in the Southern Hemisphere, our car air conditioners are going to be in big demand very soon. On a really hot day the temperature down here in the Cape can easily rise to 35 degrees celsius and the inside of any car would be roughly 3-4 degrees more. That's the kind of discomfort nobody has signed up for. The converse is just as true, I remember when I was in Germany a few years back, during November the temperature dropped right down to minus 24 degrees celsius and whilst in France it was around minus 4 degrees or less most mornings. Trying to brave such weather conditions without on-board creature comforts borders on insane. So while the temperatures hasn't peaked yet, there is still time to get your fan/blower fixed. 

Of late, somehow several VW, Audi, Seat and Skoda owners have been having issues with the fan/ac/blower not working or not working properly. On a previous blog I failed to add the fan/blower issue to the list of common problems, but believe me it is. Below are some questions asked by a few VW owners regarding their respective VW vechicle refering to the fan/AC/Blower motor.  Well the culprit is normally the Heater Fan Blower Motor Tandem Resistor with OE/OEM Number 6Q0959263A / 6Q0959263/6Q0 959 263 A, manufactured by Hans Pries. Alternatively the Hella brand replacement part with  part number 5HL 351 321-301 or 5HL351321-301. 

The speed of the 12V blower motor is controller via this series "blower resistor". It's a wire wound ceramic resistor and it does get quite hot on speeds position 1, 2 and 3. In the last position the resistor is bypassed. So if you blower isn't working on every speed it is most likely the resistor. However if you have an A/C with  a four speed switch and the blower doesn't work on any of its 4 positions, then its most likely the ground wire that's loose, burnt, poor contact, intermittent. Look behind the fan switch, there is a large 4 pin white molex connector and when its ground wire overheats, it looks discoloured, sort of lightly toasted and sometimes makes intermittent contact. On some models the motor is electrically isolated, so connect a jumper between the car body and motor earth, just to test. If the connector is faulty, the motor with spin. If it doesn't spin, check for 12V DC supply on the Red/White wire with a multimeter, if there is no supply voltage, check the fuse and the heater relay. 

BLOWER SWITHC CONECCTIONS

Red/Black - 12V supply to switch from fuse/relay box
Black/White - position 1
Yellow/Black - position 2
Yellow - position 3
Brown - from blower motor to ground/earth

Red/white - 12V supply 
Blue - position 1
Green - position 2
Black - position 3
Red - position 4 
Brown - from blower motor to ground/earth

Blower motor series resistor can be found in the glove compartment on some models

Question:

My heater fan doesn't seem to be working properly, I can feel a small amount of air blowing but I don't hear the blower motor. Please help me!

Answer: 

Read the blog!

Question:

Just bought an Audi A2 2005 and discovered defroster/heat/AC doesn't work. Is this major or should I cancel the sale? 

Answer: 

Read the blog! 

Question:

I have problem with my Jetta fan/blower that stops working, it just switched off after only owning car for two months.  No DTC codes!

Answer: 

Read the blog!

Question:

I recently noticed my interior heater/fan was becoming weak, and stops altogether at low speeds. Must I replace the motor.

Answer: 

Its very likely that the motor brushes has reached end of life. I think a new pair will give you blower a new lease on life. You didn't indicate what car you have, because yours  motor can possibly be of the  sealed type, meaning you would have to replace the motor if and only if you've exhausted the above.

Question:

My Golf's fan/blower works OK, but  after a while it makes a really loud noise like its struggling to keep turning and then it switches off. However when I hit a speed bump in the road it gives me a fright when it just turns back on. Can you help?

Answer: 

Read the blog!

Question:

Just bought a VW caddy and the fan/blower seems lazy and makes a noise that varies between loud and quite, previous owner says there is a leaf that fell down the ducting and lying on the fan. I'm not convinced because sometimes when I turn on the blower, it doesn't blow at all. Any suggestions?

Answer: 

Read the blog!

The heater fan blower motor resistor is one of those items that works on a great many VW, Audi, Skoda and SEAT cars. The list below gives you some idea  how common the problem really is. When you suspect that your heater fan thermal resistor has gone faulty make certain the part number is the same as the one you replacing it with because there is a fair amount of variation  even though there is a degree of compatibility.

Audi, SEAT, compatibility list

SEAT and Skoda compatibility list

SEAT, Skoda and VW compatibility list.


AUDI A2 (8Z0) 1.2 TDI, AUDI A2 (8Z0) 1.4, AUDI A2 (8Z0) 1.4 TDI,  
AUDI A2 (8Z0) 1.4 TDI,  AUDI A2 (8Z0) 1.6 FSI,  


SEAT CORDOBA (6L2) 1.2,  SEAT CORDOBA (6L2) 1.2 12V,  
SKODA FABIA (6Y2) 1.0,  SKODA FABIA (6Y2) 1.2,  SKODA FABIA (6Y2) 1.2,  
VW FOX (5Z1) 1.2,  VW FOX (5Z1) 1.4,  VW FOX (5Z1) 1.4 TDI,  VW POLO (9N ) 1.2,  

SEAT CORDOBA (6L2) 1.4 16V,  SEAT CORDOBA (6L2) 1.4 16V,  
SEAT CORDOBA (6L2) 1.4 16V,  SEAT CORDOBA (6L2) 1.4 TDI,  
SEAT CORDOBA (6L2) 1.4 TDI, SEAT CORDOBA (6L2) 1.4 TDI,  
SEAT CORDOBA (6L2) 1.6, SEAT CORDOBA (6L2) 1.6 16V,  
SEAT CORDOBA (6L2) 1.9 SDI,  SEAT CORDOBA (6L2) 1.9 TDI,  
SEAT CORDOBA (6L2) 1.9 TDI,  SEAT CORDOBA (6L2) 2.0,  
SEAT IBIZA IV (6L1) 1.2 12V,  SEAT IBIZA IV (6L1) 1.4 16V,  
SEAT IBIZA IV (6L1) 1.4 TDI,  SEAT IBIZA IV (6L1) 1.4 TDI, 
SEAT IBIZA IV (6L1) 1.6 16V,  SEAT IBIZA IV (6L1) 1.8 T Cupra R,  
SEAT IBIZA IV (6L1) 1.9 TDI Cupra R,  SEAT IBIZA IV (6L1) 1.9 TDI Cupra R,  
SEAT IBIZA V (6J5) 1.2,  SEAT IBIZA V (6J5) 1.4,  
SEAT IBIZA V (6J5) 1.4 TDI,  SEAT IBIZA V (6J5) 1.9 TDI,  
SEAT IBIZA V (6J5) 1.9 TDI,  SEAT IBIZA V SPORTCOUPE (6J1) 1.2,  
SEAT IBIZA V SPORTCOUPE (6J1) 1.4,  SEAT IBIZA V SPORTCOUPE (6J1) 1.4 TDI,  
SEAT IBIZA V SPORTCOUPE (6J1) 1.9 TDI,  SEAT IBIZA V SPORTCOUPE (6J1) 1.9 TDI,  

SKODA FABIA (6Y2) 1.4,  SKODA FABIA (6Y2) 1.4 16V,  SKODA FABIA (6Y2) 1.4 16V,  
SKODA FABIA (6Y2) 1.4 TDI,  SKODA FABIA (6Y2) 1.4 TDI,  
SKODA FABIA (6Y2) 1.4 TDI,  SKODA FABIA (6Y2) 1.9 SDI,  
SKODA FABIA (6Y2) 1.9 TDI,  SKODA FABIA (6Y2) 1.9 TDI RS,  
SKODA FABIA (6Y2) 2.0,  SKODA FABIA 1.2,  SKODA FABIA 1.2,  
SKODA FABIA 1.4,  SKODA FABIA 1.4 TDI,  SKODA FABIA 1.4 TDI,  
SKODA FABIA 1.6,  SKODA FABIA 1.9 TDI,  SKODA FABIA Estate (6Y5) 1.2,  
SKODA FABIA Estate (6Y5) 1.2,  SKODA FABIA Estate (6Y5) 1.4,  
SKODA FABIA Estate (6Y5) 1.4, SKODA FABIA Estate (6Y5) 1.4 16V,  
SKODA FABIA Estate (6Y5) 1.4 16V,  SKODA FABIA Estate (6Y5) 1.4 16V,  
SKODA FABIA Estate (6Y5) 1.4 TDI,  SKODA FABIA Estate (6Y5) 1.4 TDI,  
SKODA FABIA Estate (6Y5) 1.4 TDI,  SKODA FABIA Estate (6Y5) 1.9 SDI,  
SKODA FABIA Estate (6Y5) 1.9 TDI,  SKODA FABIA Estate (6Y5) 2.0,  
SKODA FABIA Estate 1.2,  SKODA FABIA Estate 1.2,  
SKODA FABIA Estate 1.4,  SKODA FABIA Estate 1.4 TDI,  
SKODA FABIA Estate 1.4 TDI,  SKODA FABIA Estate 1.6,  
SKODA FABIA Estate 1.9 TDI,  SKODA FABIA Praktik 1.2,  
SKODA FABIA Praktik 1.2,  SKODA FABIA Praktik 1.4,  
SKODA FABIA Praktik 1.4 TDI,  SKODA FABIA Praktik 1.9 SDI,  
SKODA FABIA Saloon / Sedan (6Y3) 1.2,  SKODA FABIA Saloon / Sedan (6Y3) 1.2,  
SKODA FABIA Saloon / Sedan (6Y3) 1.4,  SKODA FABIA Saloon / Sedan (6Y3) 1.4,  
SKODA FABIA Saloon / Sedan (6Y3) 1.4 16V,  SKODA FABIA Saloon / Sedan (6Y3) 1.4 16V,  
SKODA FABIA Saloon / Sedan (6Y3) 1.4 16V,  SKODA FABIA Saloon / Sedan (6Y3) 1.4 TDI,  
SKODA FABIA Saloon / Sedan (6Y3) 1.4 TDI,  SKODA FABIA Saloon / Sedan (6Y3) 1.4 TDI,  
SKODA FABIA Saloon / Sedan (6Y3) 1.9 SDI,  SKODA FABIA Saloon / Sedan (6Y3) 1.9 TDI,  
SKODA FABIA Saloon / Sedan (6Y3) 2.0,  SKODA ROOMSTER (5J) 1.2,  
SKODA ROOMSTER (5J) 1.2,  SKODA ROOMSTER (5J) 1.4,  
SKODA ROOMSTER (5J) 1.4 TDI,  SKODA ROOMSTER (5J) 1.4 TDI,  
SKODA ROOMSTER (5J) 1.6,  SKODA ROOMSTER (5J) 1.9 TDI,  

VW POLO (9N ) 1.2,  VW POLO (9N ) 1.2 12V,  VW POLO (9N ) 1.2 12V,  
VW POLO (9N ) 1.4 16V,  VW POLO (9N ) 1.4 16V,  VW POLO (9N ) 1.4 16V,  
VW POLO (9N ) 1.4 FSI,  VW POLO (9N ) 1.4 TDI,  VW POLO (9N ) 1.4 TDI,  
VW POLO (9N ) 1.4 TDI,  VW POLO (9N ) 1.6 16V,  VW POLO (9N ) 1.8 GTI,  
VW POLO (9N ) 1.8 GTi Cup Edition,  VW POLO (9N ) 1.9 SDI,  VW POLO (9N ) 1.9 TDI,  
VW POLO (9N ) 1.9 TDI,  VW POLO Saloon / Sedan 1.4,  VW POLO Saloon / Sedan 1.4,  
VW POLO Saloon / Sedan 1.4 TDI,  VW POLO Saloon / Sedan 1.9 SDI,


VW Golf 3 blower resistor
VW Amrok blower resistor
VW Sharan blower resistor
VW Touareg blower resistor
VW Touareg blower resistor
VW Polo blower resistor
VW Audi blower resistor
VW Fabia blower resistor
VW Ibiza blower resistor
VW Passat blower resistor
VW Skoda blower resistor
VW Seat blower resistor
VW Transporter blower resistor
VW Transporter blower resistor

6Q0959263A / 2D0959263 / 1K0959263A / 701959263B / 701959263D / 7L0907521B / 7L0907521 / 7L0907521A / 7L0907521B / 701959263A / 3C0907521E / 3C0907521F 1K2820015F / 6Q2907521B / 8D1820021 / 1J0819022 / 8K0820521B / 1J0819022A
74024583 / 8D0959263 / 1JO907521 / 1J0819022A 7E0959263C / 6Q0959263A / 

1J0819022A /