VW POLO

VW Polo, VW Golf, VW Jetta, VW Passat, Audi, SKODA, SEAT and other new generation VAG cars are designed with a monopoly in mind. Restated they were designed so that only service agents are supposed to do the servicing and repairs. As of 2008 all new vehicle manufacturers ascribe to the CAN-Bus protocol which is not backward compatible to older ODB II protocols. The notorious VW EPC light, Drive by Wire and Limp mode and won't rev more than 2000 rpm explained here on Volkswagen Polo Highline.

Friday, May 3, 2013

VW POLO DIAGNOSTICS

VW DIAGNOSTICS

After I completed all the minor repairs (as can be seen in my previous blog) to my VW Polo 2.0L Highline she finally went for her 90 000 kms service. But hardly did I get her back when I heard a very soft and occasional "ting, ting, ting" coming from the right front wheel. The sound was difficult to identify at first, not even the auto service technicians at the center could hear it. I found that the wheel had a few millimeters of sideways play when I jacked-up the VW Polo. This prompted me to check all the nuts & bolts and I found the nut on the tie-rod end to be loose. After tightening it, the sideways play was cured. However, it didn't cure the soft, occasional and irritating "ting, ting, ting." Twice thereafter I had the wheel off but found nothing out of the ordinary. Anyway I suspect its the right right hand side CV joint that is starting to go but it kind seems strange that a CV joint should give up the ghost round about 90 000 kms, its just way too early.

VW Amarok left hand drive double cab in snow white.

The tough smart VW Amarok Double Cab.

The 2.0L VW Polo right hand side drive shaft is very different from that of its siblings, it is much thicker and the spline that the hub slides onto, is much coarser that any other VW Polo. This drive shaft is an agents only item and its not cheap and to replace it by substitution to get rid of the occasional "ting" is a bit extravagant. My VW Polo is a very different beast from the rest of the VW Polo range and finding information for it is quite difficult. It seems every service centre has all the other manuals except that of the VW Polo Classic 2.0L highline.

VW DIAGNOSTICS

For starters it has the following odd ball ECU controlling an odd ball BBX engine rated at 84KW and 116HP.

Address 01: Engine

Controller ID 06A 906 032 PB

Component 2.0l ME7.5.10 0305

Sotware Coding Coding 00071

ENGINE TYPES:

Essentially Bxx implies VW Polo engines manufactured after 2005, whereas Axx implies engines manufactured prior to 2005 or rather between 2001 and 2005. The following engines range from 1.2L to 1.4L to 1.6L to 1.8L to 1.9L and 2.0L and include diesel engines. BMD, BBM, BME, BZG, BKY, BUD, BLM, BBZ, BNM, BWB, BMS, BNV, BAH, BTS, BJX, BBU, BMT, BLT, BBX,

The following list of Axx engines also range from 1.2L to 1.4L to 1.6L to 1.8L and 1.9L and include diesel engines, AWY, AZQ, AUA, AXU, AUB, AMF, ASY, ATD, AXR, ASZ. However the Axx, Bxx rule isn't hard and fast or cast on stone. There are VW Polo vehicles manufactured prior to 2005 with BMD, BME, BBY, BKY, BBZ, BAY,BLT engines fitted and there are some manufactured after 2005, fitted with AXU,ATD, ASY, AXR, ASZ engines.

Concept cars by Volkswagen

My 2.0L Volkswagen Polo ECU's isn't only used in 2.0L Golf, Jetta and VW Polo but also in 1.8T like the Seat Ibiza Cupra, Seat Leon, and the Seat Toledo Cupra with ME7.5.10 software.

2.0L GOLF / JETTA - ECU or Engine Management System

AWD 06A 906 032 CL 2001

AWD 06A 906 032 CM 2001

AZG 06A 906 032 DS 2001 (manual)

AWW 06A 906 032 DL 2001 (manual)

AZG 06A 906 032 FN 2002 (manual)

AVH 06A 906 032 BP 2001 (manual)

AVH 06A 906 032 FQ 2002 (manual)

AVH 06A 906 032 MC 2003 (manual)

BEV 06A 906 032 MT 2004 (manual)

BBW 06A 906 032 PE 2004 (manual)

AWP 06A 906 032 HS 2002 (manual)

AWP 06A 906 032 LP 2002 (manual)

AWP 06A 906 032 NK 2002 (manual)

AWP 06A 906 032 SK 2002 (manual)

AWP 06A 906 032 RN (6spd manual)

AWP 06A 906 032 SM (6spd manual)

BBX 06A 906 032 PC

AZL 06A 906 032 NH

AZL 06A 906 032 MN

AZL 06A 906 032 NJ

AZL 06A 906 032 NB

AZG 06A 906 032 DT 2001 (automatic)

AVH 06A 906 032 BQ 2001 (automatic)

AWW 06A 906 032 DM 2001 (automatic)

AWW 06A 906 032 GH 2001 (automatic)

AVH 06A 906 032 FR 2002 (automatic)

AZG 06A 906 032 FP 2002 (automatic)

AVH 06A 906 032 MD 2003 (automatic)

BEV 06A 906 032 NA 2004 (automatic)

BBW 06A 906 032 PD 2004 (automatic)

AWP 06A 906 032 LQ (5spd automatic)

AWP 06A 906 032 NL (5spd automatic)

AWP 06A 906 032 SL (5spd automatic)

VW DIAGNOSTICS CONT.

My 2007 VW Polo Classic 2.0L Highline is an 9N4 with a JHF 5 speed odd ball manual transmission with odd ball gear ratios and also has a obscure Immobilizer module (6Q0 920 825 C) which doubles up as the Instruments Module. This is easily visible because of the software coding. There are several dozen of other Instrument Modules none of which are compatible to the 2007 VW Polo Classic 2.0L Highline.

Address 25: Immobilizer

Controller ID 6Q0 920 825 C

Component IMMOBILIZER VDO V06

Sotware Coding 00141

Address 17: Instruments

Controller ID 6Q0 920 825 C

Component KOMBIINSTRUMENT VDO V06

Software Coding 00141

VW DIAGNOSTICS CONT.

The following VW 9N and 6N3 Instrument controllers have various coding, which is subject to other on-board equipment. The software versions in their 93c86 EEPROM range from V2 to V17 and appears incompatible to 6Q0 920 825 C. As can be seen below, only the letter suffix changes but the software is somewhat different.

Controller: 6Q0 920 825 E / Coding: 01144 = VW Polo 9N1 = software VDO V06

Controller: 6Q0 920 825 F / Coding: 01132 = VW Polo 9N = software VDO V05

Controller: 6Q0 920 825 G / Coding: 01132 = VW Polo 9N = software VDO V03

Controller: 6Q0 920 825 J / Coding: 01142 = VW Polo 9N3 = software VDO V06

Controller: 6Q0 920 825 H / Coding: 01141 = VW Polo 9N1 = software VDO V06

Controller: 6Q0 920 825 K / Coding: 01148 = VW Polo 9N = software VDO V05

TRANSMISSION TYPES:

The following list of 5 speed manual transmissions are fitted in the 1.8T Mk4 Golf, 1.8T Beetle, 2.0L Beetle, 1.8T Golf, 1.8T Jetta IV, Jetta IV 2.0L, Golf IV 2.0L, Jetta 1.8L, Jetta 1.9L, Jetta 2.0L, 2.0L Golf VR6, non of which has the odd ball JHF transmission used in the 2007 VW Polo Classic 2.0L Highline.

CDN, DZC, DZQ, EBD, EBJ, EBP, EBQ, EGQ, EGR, EHA, EHC, EGT, EKG, EKH, EMS, EMT, ENJ, EZK, FBY, FBV, FBW, FCF, EGF, EWW, EUH, GQQ, JCR, JDM, JDQ.

If you have a VW Polo Classic 2.0L Highline, you may post your VW Diagnostics report below.

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Beautiful Women in wedding Gowns.

Saturday, April 20, 2013

VW ERROR CODES

VOLKSWAGEN ERROR CODES

My VW Polo Classic 2.0L Highline has been acting-up more and more as the date for her 90 000Km service approached. The Volkswagen Auto suddenly became very heavy on fuel and she started to smoke. It wasn't grey smoke, which would imply the VW Polo was burning oil but rather black smoke which is the tell tale sign that the VW Polo is burning gasoline. I normally do about 6 liters per 100kms but with the last tank of fuel I got something like 9 litres per 100km. With the latest high price of fuel in South Africa, I just had to investigate. The EPC light problem also returned, which was triggered by the ECU that placed the Polo into "Limp Mode" once again.

Rusty water residue still on the engine cover above the VW logo.

However that's not all. My VW Polo's interior overhead lights above the rear view mirror and sun visor courtesy lights have all stopped working when I open the doors but works perfectly when switched on manually. The hooter also just gave up the ghost, but the click of the micro switch in the steering wheel is very audible when I press it. One of my VW headlight also seems to be intermittent and it appears that my oil level sensor also does'nt work either. My VW air conditioner stopped working and my VW left tail bulb fused again and the reverse light is intermittent. I was told that it goes on or flickers whilst I'm driving. But worst of all my VW Polo overheated whilst driving in peak hour traffic and the fans didn't even come on. When I pulled the bonnet release, the little lead ball at the end of the cable snapped off. Consolation I noticed the steam coming out from under the bonnet before the heat gauge was at 100 degrees. To add insult to injury, normally at approx 20 kph all the doors of VW das auto locks, but lately the front passenger side door unlocks itself mere seconds after it locks. This is a security risk and with all the other problems I've been experiencing, I just had to connect the VW to a diagnostic tester. This turned out to be a weekend job when the following Error Codes popped up.

Chassis Type: 9N3 - VW Polo
Scan: 01,02,03,08,09,15,17,19,37,44,46,56,69

Address 01 -------------------------------------
Controller: 06A 906 032 PB
Component: 2.0l ME7.5.10 0305
Coding: 00071
Shop #: WSC 01120
VIN: AAV ZZZ 9NZ 7Uxxxxxx / VWZ7Z0G5248478
Readiness: 0000 0000

SOME ERROR CODES:-

VW, Polo Highline, Polo 1.9 TDi, Volkswagen beetles, Jetta, VW Polo cross, Passat, Polo GTi, Bora, Volkswagen bluemotion, Polo Classic, Polo 1.9 tdi, VW Polo blue motion, Cross Polo, VW Golf, Beetle, Audi, VW blue motion, Skoda, VW Touran, VW Touareg, VW Tiguan, VW Amrok, VW Rabbit, VW Caddy, VW Phaeton, VW Vento, VW Kombi, VW Transporter, VW Lupo and VW Vivo - Error Codes

VW Error code 16716 P0332 - Knock Sensor 2 (G66): Signal too Low - Intermittent
VW Error code 17511 P1103 - Oxygen (Lambda) Sensor Heating: B1 S1: Performance too Low
VW Error code 17796 P1388 - Control Module Malfunction - DBW Throttle Monitoring
VW Error code 18010 P1602 - Power Supply (B+) terminal 30 Low Voltage
VW Error code 18041 P1633 - Accelerator Position Sensor 2 (G185): Signal too Low
VW Error code 18047 P1639 - Accelerator Position Sensor 1/2 (G79/G185): Implausible Signal
VW Error code 18048 P1640 - Internal Control Module: EEPROM Error
VW Error code 18090 P1682 - Powertrain Data Bus: Implausible Message from ABS Controller
VW Error code 18104 P1696 - Powertrain Data Bus: Implausible Message from Steering Column Controller

Turns our that ECU CAN bus edge connectors were corroded which solved P0332, P1682, and P1689. The P1602 is not really considered an error since it will always be present in the ECU if or when the Battery was disconnected. P1388, P1633 and P1639 are related to accelerator pedal sensors and once the pedal is replaced that problem will be solved, other than that, the VW Polo drives perfectly normal. The Internal Control Module, error P1640 however is going to take a bit longer to solve since it appears that several of my VW module's coding values has somehow changed on their own. But most of all I'm glad I solved the black smoke problem. I found that the wire of the Oxygen sensor was burnt onto the exhaust pipe and shorted out the sensor. So I'm back to 6 litres per 100Km.

Radiator relay controller destined to be replaced since neither of the fans operate.

There were no errors on the ECU for the overheating radiator and when I removed the bonnet release cable I saw that the bonnet open sensor / switch wire was broken off. I traced the heating problem to the relay (picture above) and while I was under the engine I noticed that the Air Conditioner compressor wires had frayed and were dangling loose.

Before and after - Air Conditioner Compressor wires frayed and somehow broke off

Before and after - Bonnet open/close micro-switch/sensor with wires reattached.

Oil level sensor wires hardened and became brittle resulting in no electrical connection

I cut off the hardened pieces of wire, tinned them with solder and reconnected the wires to the oil sensor with electrical block connectors since the terminals initially used by VW didn't seem to last very long. The block connector appears to makes a much better connection.

The plastic insulators on the spade terminal couldn't withstand the heat of the cool blue bulbs.

VW VAG - Volkswagen error codes and VW Electronic Module diagnostics will be dealt with in subsequent blogs, starting with Engine Modules for the Polo 9N , then ABS Modules then Airbag Modules.

Thursday, March 7, 2013

WHY ENGINE LIGHT COMES ON

EPC LIGHT

Seeing a VW or a Volkswagen or Polo da Volkswagen or a VAG car or a new Polo on tow, is becoming an all too familiar site, - view picture below. VW cars are seen piggy-backed and carried to service centers on a daily bases because VW owners are encountering serious trouble with their Volkswagen cars.

Many Volkswagen drivers are often stranded on the high ways or freeways whilst driving to and from work because their VAG cars are throwing tantrums, by going into limp mode and turning on the EPC light. Most VW drivers have no idea why engine light comes on.

I've been late for meetings on several occasions because of this. On a few others, I couldn't make it to the bank in time because the Electronic Power Control -EPC- circuit incapacitated my VW Polo Classic 2.0L Highline. The worst was when I took my daughter to the dialysis clinic and the Electronic Power Control (EPC) light came on, because I ran over a speed bump a little too fast. This resulting in "Limp Mode" causing my daughter to be substantially late for her dialysis session. This could have been a life or death situation but fortunately it wasn't.

I took this photo with my cell phone. The picture quality really isn't good, so therefore the
Bluemotion badge to the left of the right side tail light isn't clear at all. But I couldn't pass-up
the opportunity to capture a VW Bluemotion 2012 loaded on a roll-back.

Anyway, lets look at why this very risky and inconvenient issue haunts most VAG car owners. All Drive-by-Wire cars (since 2000) has an Electronic Power Control (EPC) light. The EPC dashboard warning lights are not exclusive to VW or VAG cars but affects most other new cars regardless of its manufacturer though the common denominator is Drive-by-Wire and an Engine Control Unit (ECU) often called the Powertrain Control Module (PCM) with an embedded microcontroller supplied by the same manufacturer. EPC stands for Electronic Power Control which is controlled by the ECU (Engine Control Unit). In essence the Engine Control Unit (ECU) is a microcontroller with associated circuitry which control the sub-modules in the car, all connected together by either OBD II or CAN-Bus. Certain outputs from these sub-modules can activate the Electronic Power Control circuit, especially if the reason for sending its signals to the ECU (Engine Control Unit) could cause damage to the engine or is a danger to the passengers. For example, if the car runs out of oil, or if the emissions exceed the prescribed level, or if the car hits a speed bump a little to hard or if a brake bulb fails.

In the first case the oil level sensor will detect that the lack of oil in the crankcase and since there is a possibility the engine may seize-up, it sends a pulse train to the PCM to activate the Electronic Power Control (EPC), which cuts the power to the engine, making the car go into "Limp Mode" and switching on the EPC warning light. In the second case the lambda sensors on either side of the catalytic converter will detect the fuel rich exhaust fumes and send a pulse train to the PCM to activate the Electronic Power Control (EPC), which cuts the power to the engine making the car go into "Limp Mode", thereby limiting carbon pollution and and switch on the EPC indicator light (epc warning light) . In the third case the engine knock sensors will detect the suspension knock as the car hits the speed bump and will send a pulse train to the PCM to activate the Electronic Power Control (EPC), which cuts the power to the engine making the car go into "Limp Mode" and switch on the EPC dashboard light. In the fourth case, one of the Electronic Control Unit or Body Control Modules (BCM) sensor will sense that a brake light is open-circuit, send a pulse train to the PCM to activate the Electronic Power Control (EPC), which cuts the power to the engine making the car go into "Limp Mode" because in that condition the car is not roadworthy. The EPC dashboard light is a very graphic demonstration that there is something amiss in you VAG that needs to be remedied.

There are several other sensors strewn throughout the car and many of them can have an effect on the Engine Control Unit (ECU) and cause the EPC light to come on. Sometimes when the EPC fault light comes on, it may be a spurious error, based on past driving cycles. A driving cycle is calculated from the time the engine starts and drives -which should be a min 5 minutes- until the engine is switched off. It could take three drive cycles to clear a spurious error but if the fault persists it has to be diagnosed on a VAG-COM diagnostic tester.

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Here are some Non Volkswagen Websites I highly recommend,

http://electroniques.blogspot.com

http://photojani.blogspot.com

http://expowp.blogspot.com

VAG

VW DIY

In the not so distant pass, whenever something went wrong in your VW, Polo, Jetta, Passat, Audi, Seat or Skoda, you could do one of two things. Either take it to a VW specialist to have it checked out or you could fix it yourself, if you are a hands-on, DIY kind of person. Nowadays the latter option has faded away into obscurity. With the stream of problems VAG cars are having, many of us are in the dark regarding repairs. We make educated guesses, replace parts by substitution, often costing huge amounts of money for repairs and the fault still persists. Below I have out-lined some of the problems I have encountered and with any luck shed some light on the problems you've been having with your VAG car. But before I go any further you may be itching to ask "What is a VAG car?"

Well, VAG stands for Volkswagen-Audi GMBH in Germany, also refers to Volkswagen Aktiengesellschaft or Volkswagen AG for short and Volkswagen-Audi Gelelschaft (Geleslschaft means Association). In essence, it's the same, exact and identical group. And any car manufactured or sold by them is referred to as a VAG car. Amongst these are, VW, Polo, Jetta, Passat, Audi, Skoda, Touran, Tauareg, Beetle, Tiguan, Golf, Porsche, Amrok, Rabbit, Bentley, Bugatti, Bora, Phaeton, Vento, Kombi, Transporter, Lupo and the Lamborghini, each one with a different engine with varying capacities with obscure three letter abbreviations like, BBX, AAF, AEX and APE amongst many others. However many of them have the same or similar Electronics Bosch Motronic system hardware with software ranging from ME 5.x to ME 7.x, with several support modules in common, networked to the OBD II / OBD2 (On-Board Diagnostic System ver. 2) or Can-Bus (Controller Area Network) standard.

The VW Polo 2007 with new Bluemotion technology can switch its engine off
when it comes to a halt, yet plagued by the legacy VW EPC light problem.

The idea behind this is so that only the Volkswagen dealership technician are supposed to do the servicing and perform repairs to your car. The VW car manuals specifically discourages anyone other than qualified or trained mechanics /auto-electricians and technicians or mechanicians to perform servicing, especially changing codes and performing readiness test. Under the OBD II and Can-Bus standard, an ECU (Engine Control unit) interfaces with various other modules fitted in the car and controls and manages all sub-circuits. For example, Central Electronics Module, ABS module, Temperature Control Module, Speed-o-cruise Module, etc... When one of these modules detects a fault with one of its components, it registers a error in the non-volatile memory. Lets say you have a front wiper motor problem and it just wont work, but the fuses are OK. Even if you suspect the wiper motor as faulty and it actually is faulty and you replace it, the new wiper motor still wont work after its been replaced and switched on. You first have to clear the error or errors from non-volatile memory with a diagnostic tool. Then and only then will it work.

I've had the same results with my power steering which just wouldn't work after some work was done to my car and in the process the Power Steering Motor was disconnected. When it was reconnected the power steering was very stiff and difficult to steer. After going through the entire process of checking and back-tracking it still didn't work. Eventually, when the diagnostic tester was plugged in, two errors codes showed up. The first indicating that the +30V supply had dropped to an unreliable level and the second a power steering error. The first was because the battery was disconnected and the second was because the power steering plug was disconnected. After erasing the two error codes from the non-volatile memory, the power steering work perfectly normal.

I can assuredly say that I am not alone or rather that my car trouble is not unique, neither am I the only VW owner having car trouble (see previous blogs). It appears that my 2007 Polo Classic Highline shares most of the problems listed below with my fellow VW owners. There are probably hundreds if not thousands of other VAG car owners experiencing the same issues with their cars as I am experiencing with mine. Here are just a few of the problems that my fellow VW owners shared with me :-

"VW polo dashboard brake light stays on" / "EPC instrument fault indication light is on" / "VW polo warning lights on dashboard" / "VW polo classic is showing epc light, starting and dying" / "polo dashboard controls" / "VW polo warning lights off power steering" / "warning light on dashboard" / 2007 volkswagen polo problems" / "audi electronic power control indicator" / "won't rev" / "VW Polo EPC Warning Light" / "golf mk4 dashboard warning lights" / "epc instrument fault indication" / "VW door key problem" / "VW polo accelerator position sensor (g79)" VW throttle body sensors"

NB! Fellow VW drivers found this site to be helpful and was interested in checking out the following sites as well.

expowp, photojani, controversy365, nerdytoys, lovelifelovehealth, sightsofcapetown, sowpbox, electroniques, blogspot-at, photo-magix, godssites, glycomix, arth-ritis, forex-bid, foodsofthecape, languagesbarrier, pimpyocar, e-gimos.

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