Wednesday, October 26, 2016

HOW TO FIX AN EPC PROBLEM

HOW TO FIX AN EPC PROBLEM

Electronics have taken the motor industry by storm, so-much-so, that electronic black boxes and discrete components have come to replace several mechanical systems. Case in point, Drive-by-Wire system, where a mechanical cable is replaced by an EPC (Electronic Power Control) system. Or a shared coil or carburetor is replaced by a set of individual electronically controlled coils or electronically controlled injectors, respectively . As a result, providing us with increased safety features, tighter and better engine control, additional creature comforts, convenience and so much more. 

Virtually every system in the modern day car is digitally controlled by a some Electronic control Unit (ECU) or a bank of dedicated on-board computers  distributed throughout the car, all of them networked to a Central Bus System. There are numerous bus systems used in electronics but CAN bus developed by Robert Bosch in 1986, has quickly gained acceptance into the automotive and aerospace industries. With the continued development of more complex ECU applications,  much larger quantities of data needed to be  processed, scores of more signals needed to be measured, and a growing number of other parameters needed to be optimized. 

CAN bus was the answer to surmount these problems though it is essentially a serial bus protocol used to inter connect individual sub systems and sensors as an alternative to conventional multi-wire looms. In a nutshell, cars have gone electronic processors, is firmware based, software driven and data analysed, artificially semi-intelligent and electronically complex.  All of a sudden automotive mechanics needed to learn loads of new words like microprocessor, microcontroller, quantitative analysis, electronic engine-management systems, potentiometers, sensors, signal processing, frequency response, memory-mapped  let alone how their individual functions. 

To add insult to injury, abbreviations like Controller Area Network (CAN), CPU (central processing Unit), RAM (Random Access Memory), EPROM (Electronically Programmed Read Only Memory), LAN  (Local Area Network), ADC (Analogue to Digital Converter), distributorless ignition system (DIS), etc, just flooded the motor vehicle repair market. 

Talking about abbreviations, EPC, is the official abbreviation for Electronic Power Control when referring to the Drive-by-Wire Torque circuit,  though it also stands for Electronic Pressure Control when referring to the Automatic Transmission.  When the Torque control EPC circuit fails for whatsoever reason, the  EPC Warning Light (K132) located in the instrument cluster lights up, which then could cause the car to enter into "limp mode", depending on the severity of the problem. Limp mode is a protective state that the car's ECU enters into when it recognizes that there is a problem with it's logic program. 

For example, when an expected signal value originating from a sensor varies significantly from the predetermined program  specification, the ECU then enters into a secondary/ emergency programme in order to protect the engine / transmission from damage. The ECU is constantly expecting a regular stream of signal values from various sensors, like for example the Throttle Position Sensor, or the Mass air Flow Sensor, or the Engine Speed Sensor, or the temperature sensor, etc. As long as these signals stay within specified parameters for certain operating conditions, the ECU performs faultlessly at controlling the engine. 

Due to  the rapid expansion of electronics in motor vehicles, automotive mechanics in general were over whelmed by the introduction of this new evolution in technology and as a consequence didn't stay abreast of automotive electronics, thus now seem to have great difficulty in solving electronic problems on client's cars. Replacing parts indiscriminately with the hope that they get lucky and that the actual faulty component is among the suspected parts that were replaced.  

Many, many, many VW, Audi, Skoda, and Seat owners can testify to this, since most have first hand experience of taking their vehicles into the service agent, only to get the car back after having to foot an enormous bill for replacement parts that probably weren't faulty in the first place, only to discover later that the problem the car was taken-in for, still persists.  EPC problems essentially have most VW "mechaicians" by the short and curlys.  But an EPC problem is not that difficult to eliminate if checked systematically instead of trying to trace it by replacing components by substitution.

DESCRIPTION OF HOW THE EPC WORKS

When the ignition is initially switched on, the Motronic Engine Control Module (ECM) performs a quick self diagnosis of all components that are important for the correct functioning of the Electronic Power Control. If all components pass the  diagnostic test the EPC light goes out. However, should  the Electronic Power Control (EPC) Warning Light not light-up when ignition is switched on, or if a  malfunction  is detected in Electronic Power Control system whilst the engine is idling, the Motronic Engine Control Module (ECM) will turn on the Electronic Power Control (EPC) Warning Light, sort of constantly.  When this happens, a DTC entry is made in the Motronic Engine Control Module, then its time to scan for Diagnostic Trouble  Codes with a scan tool.

NB! 

EPC also stands Electronic Power Control but also stands for  Efficient Power Conversion (EPC), Emergency Power Cut (EPC), Error Protection Code  (EPC), Event Process Controller (EPC), Embedded Personal Computer (EPC), Embedded Programe Controller (EPC), Erasable Programmable Chip,  Electronic Page Composition (EPC), Editorial Processing Center (EPC), Electronic Publishing Center (EPC), Energy Performance Certificate (EPC), Engineering, Procurement and Construction (EPC), Earnings per Click (EPC), Electronic Pressure Control (EPC), Electronic Product Code  (EPC), Enterprise Planning and Control (EPC), Every Penny Counts (EPC), Earth Population Control (EPC), Enhanced Power Control (EPC), 

....To continue.....

Saturday, August 20, 2016

VW/AUDI ENGINE/ RADIATOR COOLING FAN CONTROL MODULE

VW/AUDI ENGINE/ RADIATOR COOLING FAN & CONTROL MODULE

The radiator is an integral part of each and every VW, Audi, Skoda and Seat vehicle. Its main objective is to keep the engine oil cool which in turn keeps all the moving parts of the engine cool. Most cars have a radiator fan with a separate fan for the air conditioner however, VAG vehicles have an integrated Radiator and Condenser Fan Assembly,  as can be seen in the image below. Be that as it may, it is not a one size fits all situation. Virtually every VW, Audi, Seat and Skoda vehicle category has a slightly different fan which is very evident when looking at the different three character alphanumeric prefix and the alpha suffix in their part numbers. View the list below to see what I mean.
Radiator and Condenser Fan Assembly.  The fan on the right is 360mm in diameter
with a 4-pin main connector rated at 300W.
  The fan on the left is 295mm  with a 2-pin
female connector, and rated at 200W. 
The flip side of the Radiator and Condenser Fan Assembly

Be aware that a VW Polo 9N and 6R have different fans, an Audi A3 and a Q7 have different fans, a Skoda Fabia and a Roomster have different fans, a Seat Ibiza and a Seat Leon have different fans and the same and the same goes for Passat, Golf, Beetle, Tiguan, Touran, Fox, Transporter, Jetta, etc...  Having said all that, suffice to say that all these fans are troublesome, they burn out, the fins disingrates, they go open circuit and I've even known a few to go short circuit and blow its 30 amp fuse.

VW THERMOSTATICALY CONTROLLED  RADIATOR FAN 

6Q0 959 455AF Engine type: BBX - VW POLO
6R0 959 455D  Engine Code: Polo Vento
6Q0 959 455AE Engine Code: BZG - Fabia,
6Q0 959 455AE Engine Code: BMS -  Fabia, Roomster
6Q0 959 455 N Engine Code: BNM, BAY, BNV, - VW Polo, Fox,
1K0 959 455P  Engine Code: BSE  - Audi A3
1K0 959 455N  Engine Code: BLR - Passat
1K0 959 455DH Engine Code: BMY - VW Touran
1K0 959 455P  Engine Code: BMY -VW Golf
1J0 959 455   Engine Code: AKQ - VW Golf
1K0 959 455ET Engine Code: CFG - VW Tiquan
1K0 959 455FR Engine Code  CFGB - VW Tiquan
6Q0 959 455AD Engine Code: CAYB -VW Polo
6R0 959 455   Engine Code: CFWA - Skoda
6Q0 959 455AD Engine Code: AMF - Polo, Skoda Fabia, Seat Ibiza
6E0 959 455A  Engine Code: AAA - VW Golf, Passat, Polo
7L0 959 455F  Engine Code: CBFA, CCTA - Audi Q7
8D0 959 455   Engine Code: AFB - Audi A6/A8, VW

This list is by no means complete and there are probably a few dozen more variations. These fans are made  by Brose 
(Puebla/Mexico),   Behr Hella Services GmbH (Germany), Wenzhou (Mainland China) and several other an OE manufacturer expressly for the Volkswagen Group with OEM replacement part numbers 1K0959455DT, 1K0959455CQ, 1K0959455N, 1K0959455DL, 1K0959455FE, 1K0959455FJ, etc.  These are predominantly the 300W, 4-pin main connector with 2-pin female secondary connector type, guaranteed to fit the following VW and Audi models. 

2006-2013 Audi A3
2008-2015 Audi TT
2009-2015 Audi TTS
2012-2014 Audi TTRS
2012-2012 Volkswagen Beetle (up to 3/4/2012, VIN specific)
2009-2015 Volkswagen CC
2007-2015 Volkswagen EOS
2006-2014 Volkswagen GTI
2010-2014 Volkswagen Golf
2005-2012 Volkswagen Jetta (up to 3/4/2012, VIN specific)
2006-2010 Volkswagen Passat
2012-2012 Volkswagen Passat (up to 3/4/2012, VIN specific)
2008-2008 Volkswagen R32
2006-2009 Volkswagen Rabbit
2009-2015 Volkswagen Tiguan

The 360mm Radiator fan, notice the four wires in the plug, two thick and two thin.

However, in order to avoid future problems, it is highly recommenced by the fan manufactures that the controller module should be replaced together with correct fan.  The list below are just a few of the radiator controller modules / relays that support the glut of VAG fans. These relays are  VIN specific, so please verify existing part number with the supplied part for correctness.  These contollers are manufactured in Hungary,  Brazil, and Germany. 

1H0 919 506 A -VW Golf MK2 MK3, GTI 8V
1H0 919 506 B - VW Golf MK2 / MK3 GTI 8V
1J0 919 506 G - VW Golf, Lupo, caddy, Audi A3
1J0 919 506 K - Seat Arosa, Leon, Toledo, Skoda Octavia
1J0 919 506 L -  VW, Audi, Skoda & Seat
1J0 919 506 M - Polo, etc
1J0 919 506 P -Golf MK4 , etc,
1J0 919 506 Q - Golf Mk4 GTI, etc

4 and 14 Pin radiator controller module

4 and 10 pin radiator controller module



As mentioned earlier, the fans and controllers are troublesome but the German manufactured version is a lot better and thus last much longer but it is also pricier.  Notice that the main part number on both the above images are the same except for its prefix. The real difference is that the top module has 14 contacts on its right side connector whereas the middle module has only 10 and the bottom module has only 6.  The 2 images below gives you  good idea of the variations in modules. The final image shows how these modules burn.


Main and secondary connectors with 4 and 10 pins respectively.
The secondary plug has 14 pins

This is what happens to the modules made in Hungary and Brazil.

What is an EPC light? What is an EPC warning light? What is an EPC light on Volkswagen? What Is the VW EPC Warning Light? What is the EPC light on a Volkswagen Jetta? What is EPC on a Volkswagen? What does it mean if the EPC warning light comes on in a Volkswagen? Volkswagen - EPC Warning Light, What does an EPC light on the dash of a Polo match car mean? EPC light came on and lost all power.  The EPC warning symbol came on today while driving. EPC Light and stalling. EPC light came on and can't start the engine. EPC light on, what does it mean ? EPC light and engine check light. EPC warning light. Epc light. EPC + power loss/no boost.  Do not exceed 4000 rpm  EPC light.   EPC error where the car shakes terribly.  ESP EPC & Engine Light ON.  EPC Light and Stalling. Polo bluemotion 58 plate and a yellow engine light came on. I read the manual but still not sure something to do with the exhaust?? A little help as my wife needs the car for work.2002 1.6L GOLF, EPC light on. POWER LOSS An EPC light will appear on the dash randomly whilst driving. Once it is on, there is a noticeable loss in power and it stays this way until the... volkswagon polo epc warning.step by step guide to turn light off please, preferably without visiting expensive vw garage. Have diagnostic computer to see code! EPC light came on and engine will not rev higher. I have a vw polo and the EPC warning light has come on what should i do? Orange light 03 vw polo. VW Polo Map sensor fault code idling poorly. EPC light on my dashboard 2001 vw polo. It has something to do with the engine management, retarding the power of the engine.