Saturday, June 29, 2013

EPC LIGHT - REVISITED


VW POLO EPC LIGHT 

Most VW Polo, Golf, Audi, Passat and  Skoda  vehicles and probably every other VAG cars appears to have problems lately. In one sentence, the most common of these problems seems to be on obd diagnostics the culprit being the  wiring that interconnect all the electronic modules, aka the OBD II / CANbus. Virtually every car diagnostic test done on several different VAG cars produced the same faults. This implies that they are common, since they are recurring on different owners cars.  I can relate to this from my Television engineering days, when several same-make and same-model televisions all appeared to give the same problems. These VAG cars all seemed to have Intermittent / Implausible messages on the Data Bus and its highly unlikely that it could be the electronic modules themselves that are intermittent. Should this be the case, each and every one of these VAG cars then needs to be recalled because it looks like a defective design or assembly line problem.  But that's  wishfully thinking on my part which will obviously be met with and answer like - highly unlikely.

Wiring harnesses and cable assemblies for electrical buses interconnecting several MOSFET fast switching electronic modules each having an edge connector / plug whether it is gold plated or not, has parasitic capacitance. Add this  to the edge connector resistance and crimped wire contacts inside the plugs makes for interesting intermittent connections. The following list are faults /errors  that showed up on diagnostic tests on cars with EPC light problems, which  gives you some idea what I'm referring to. I've  abbreviated "Powertrain Data Bus" to PDB: in order to stop each fault from running onto two lines. Excessive comms errors and internal control module memory error intermittent are common faults caused by wiring harnesses.



SCAN TOOL ERROR CODES

1) 01312 - Powertrain Data Bus:  - Faulty

2) 18034 - PDB: error P1626 Missing Message from TCU  (Transmission Control Unit)
3) 18043 - PDB: error  P1635 Missing Message from A/C Controller
4) 18044 - PDB: error  P1636 Missing Message from Airbag Controller
5) 18058 - PDB: error  P1650 Missing Message from Instrument Cluster
6) 18270 - PDB: error  P1862 Missing Message from Instrument Cluster 

7) 18055 - PDB: error  P1647 Check Coding of ECUs
8) 18056 - PDB: error  P1648 Failure
9) 18045 - PDB: error  P1637 Missing Message from Electric Load Controller
A) 18097 - PDB: error  P1689 Implausible Message from Elect. Load Controller

B) 18104 - PDB: error  P1696 Implausible Message from Steering Column Controller
C) 18107 - PDB: error  P1699 Missing Message from Steering Wheel Electronics

D) 18057 - PDB: error  P1649 Missing Message from ABS Controller
E) 18259 - PDB: error  P1851 Missing Message from ABS Controller
F) 18090 - PDB: error  P1682 Implausible Message from ABS Controller
G) 18261 - PDB: error  P1853 Implausible Message from ABS Controller

Implausible signal means that it is "intermittent", even intermittent at the time the diagnostic tester was interfacing with the ECU's, TCU's, STC's ABS's, A/C etc... "Missing Message" implies absolutely no contact (Open Circuit) with the respective modules at the time of testing. Since VAG cars became inundated with electronic modules, our individual cars each have a few hundred more electrical connections than the previous generation of cars each and everyone of them subject to the tresses and strains of  the bumps on uneven roads and spirited driving. Add engine heat, steam, dampness and other weather conditions to this equation and suddenly these connections become tarnished over time. Tarnished connections are certainly not electrically sound and one way to clean these contacts is with contact spray but graphite or a grey ink rubber would be more effective to clean the tarnish off the gold plated PCB edge connectors. The Bentely VW manual suggest replacement of the whole wiring harness if  any problems arise but it comes at a cost of  $798.00 and that's for a 2007 VW Polo highline. I would hate to know what it would cost for a 2013 Volkswagen Touareg or 2013 Volkswagen Amrok not to mention 2013 Audi A8 or Audi TT .

VAG cars are really nippy and a joy to drive and I'm certain the bulk of VAG car owners enjoy spirited driving but many many VAG car driver probably regret this since they only experienced  EPC light troubles after they did some real spirited driving. I know this is absolutely true for Audi TT drivers who complained that their cars were fin until they gave it a nice workout. It is obvious centrifugal force, torque, tension, flexing, wind resistance and inertia plays their respective roles on the plugs and connectors. The EPC Light problems above, D through G appears to dictate that the ABS Controller is faulty or its edge connector / plug is faulty or the harness is faulty. B through C suggest that the Steering Wheel Controller is faulty or its edge connector / plug is faulty or the harness is faulty is causing the EPC light  to light up. Numbers 5&6 seems to favour the Instrument Cluster as faulty or its edge connector / plug is faulty or the harness is faulty which causes the EPC light to light up. Number 9 and letter A seems to blame the Electric Load Controller for triggering the EPC light. Numbers 1-4 and 7&8 seems to suggest some other electronic module caused the EPC light to light up. All these modules have one thing in common, they are all associated with the Powertrain Data Bus. In essence any module associated with the Powertrain Data Bus can cause the EPC light on VW Polo or other VAG cars to trigger.


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Friday, June 14, 2013

VW BLUEMOTION


VW BLUEMOTION VS SIEMENS ELECTRIC

In our modern world with its ever rising energy demand, environmental issues have become everyone's concern, and it's imperative that each and every one of us  do our bit for the environment, companies and corporations included.  With our limited fossil fuel and oil resources, alongside stricter environmental and climate protection regulations we need to rethink our driving habits to achieve greater future sustainability and energy efficiency.  Several large corporations across the globe are slowly becoming more environmentally aware through public pressure and their production of “greenovation”. Volkswagen South Africa is such a company yet there are still numerous other large corporations totally negligent, even unthinking, almost Eco oblivious, hard at the process that is destroying our planet day by day.

Volkswagen launched VW Polo BlueMotion and the “Think Blue” concept in 2005, which is their holistic approach to ecological sustainability and underpins their brand philosophy and their commitment to global environmental responsibility. Some time in  2012, Volkswagen announced its intention or rather its aspiration to become the leading car manufacturer in the world by 2018. By which time, they  intend to reduce energy and water consumption, waste, solvent emissions and CO2  emissions by 25% relative to its 2010 values. Volkswagen’s Uitenhage Plant is already hard at work to become a “Think Blue Factory”  since its new world-class press line consumes an astounding 30% less energy than conventional press lines. Currently Volkswagen's award winning Polo BlueMotion is the most successful environmentally friendly car label, using the most fuel efficient BlueMotion  technologies which has subsequently been extended to Volkswagen Golf BlueMotionVolkswagen CC BlueMotion, Tiguan  BlueMotion, New Touareg BlueMotion.


VW Polo BlueMotion 1.2L Stop-start technology - 4.4 Litres/100km

Electric vehicles 

BlueMotion technology is really great and suffices as eco-tech for today's car  however, will Volkswagen really  become the leading car manufacturer in the world by 2018 in the presence of Electric vehicles  which can be powered by electricity generated from renewable sources of energy.  German Electronics Company Siemens showcased its "eChopper" electric bike and eRuf roadster at the COP17 in Durban late in 2011. Siemens is not a car manufacturer but with many years of experience in energy, mobility, and IT, is
perfectly positioned to pioneer a new era of sustainable transport.

Way back in 1881, German Electronics Company Siemens  rolled out  the world’s first electric tram in Berlin and by 1905, Siemens built the first “Elektrische Viktoria” (“Electric Victoria”), an  electric car used as elegant hotel taxis or delivery vehicles in Berlin. By the 20th century, Siemens became the leading supplier of electric drives for railways. Today Siemens uses its extensive expertise in energy, mobility, and IT to refine the technology for electric cars and large-scale fleet trials.  Since April 2013, approximately 100 Siemens employees has been test driving electric cars for everyday use and assist to optimize the interaction between the electrics cars and the electricity grid. Just five years ago, this seemed to be a vision for the distant future.

Porsche eRuf Roadster courtesty Siemens


Quiet electric cars  with  zero-emissions are especially ideal for cities and are currently the only means of transport that also enables a clean solution for individual mobility. Electric cars, electric bicycles, and electric scooters are already gaining in popularity for local usage and if  electric cars are to make a real breakthrough, the  automotive and electrical industries need to form joint ventures to setup the necessary infrastructure like charging stations, for electromobility.  Is there a future for Bluemotion technology  if  German car manufacturer Volkswagen  and German Electronics giant Siemens decide to produce our electric VW's of the future? VW has the  e-Co-Motion electric van and the XL1 hybrid. Siemens is currently one of the top automobile electronic module manufacturers. The first images below is VW's  electric concept car and the second is VW's first electric production car called  the  e-Up capable of 150 km per charge.


Volkswagen's single-seater electric concept car called the Nils.
VW's first first eGolf 


Wednesday, May 15, 2013

Volkswagen Electronics


VOLKSWAGEN ELECTRONICS

AUDI  MODULE CODING

Electronics has taken over the modern day car, a trend that started prior to 1994. Since then  motor vehicle electronics technology has taken on a completely different form. With the advent of OBD (On-Board Diagnostics) there has been strides to standardize automotive electronics in all vehicles with relative success. With the arrival OBD II automotive electronics standardization was close to uniform, however there were other derivatives, among which was EOBD (European OBD). Thereafter, CAN-Bus was introduced which is now the defacto standard for all cars built after 2008 internationally. All cars built from 2012 only sports CAN-Bus,  and are not backward compatible to older ODB II protocols, like KWP2000 for example. This move implies every auto technicians who financially invested in ODB II scanners will have to get the latest equipment in order to scan the latest cars. Just look at the Audi Q7 with its 50+ electronic modules all of which are CAN-Bus only. 
Audi Q7 has more than 50 Electronic Modules.

The hexadecimal list of Electronic Modules below are just an idea of what can be expected in current and future motor vehicles many of them having as many as 24 different module versions, many modules are incompatible with the various models of Audi, VW, Skoda and SEAT, each with its own features and coding.

02: Auto Trans
05: Acc/Start Authorization
07: Control Head
08: HVAC
0E: Media Player 1
0F: Digital Radio
11: Engine II
13: Auto Dist. Regulation
15: Airbags
16: Steering Wheel
18: Aux. Heater  
19: CAN Gateway
1E: Media Player 2  
20: High beam assist
22: All Wheel Drive
28: Heating / Air Conditioning (Rear)
2E: Media Player 3
34: Level Control
36: Driver's Seat
3C: Lane Change
3D: Special Function
42: Door Elect, Driver
47: Sound System
4F: Centr. Electr. II
52: Door Elect, Pass
55: Headlight Range
56: Radio
57: TV Tuner
5C: Lane Maintenance
61: Battery Regul.
62: Door, Left Rear
65: Tire Pressure Monitor
67: Voice Control
6C: Back-Up Camera
6D: Trunk Electronics
72: Door, Right Rear
77: Telephone


AUDI : - SOME ENGINE CONTROL UNITS AND CODINGS




Engine:

Controller:     8E0 909 518 A,
Coding:         0011581 or 0016711

Controller:    8E0 909 518 AA

Coding:         0011501

Controller:    8E0 909 518 AC
Coding:        0004501 / 0004581

Controller:     8E0 909 518 AF
Coding:         0016701 / 0016751 / 0016581

Controller:     8E0 909 518 AK
Coding:         0016711 /  0016751 /  0016501

Controller:     8E0 909 518 AL
Coding:         0011584

Controller:     8E0 909 518 AS
Coding:         0011511

Controller:    8E0 909 518 AQ  
Coding:        0011501

Controller:     8E0 909 518 F
Coding:         0016701 or 0016751

Controller:     8E0 909 518 G
Coding:         0016581


 AUDI Automatic Transmission 
codings will be covered in Future Blogs.

VIN Number identification 
will also be covered in Future Blogs.

Volkswagen’s new modular architecture 
will also be covered in Future Blogs.


Saturday, May 11, 2013

VW AIRBAGS


VW AIRBAGS CODING

Virtually all modern cars are fitted with airbags and VWs or VAG cars are no exception.  Airbags are specifically designed to protect the driver and  passengers in the unfortunate case of an accident.  Having airbags gives drivers and passengers a certain sense of safety and assurance should they be involved in an accident that injuries sustained could be kept at a minimum. Airbags are manufactured from a parachute-like material and they instantly inflates with a compressed gas,  when the automobile in which it is fitted to meets with a collision.


VW Polo Classic 2.0L highline facelift airbag controller
However it is becoming increasingly common for airbags to deploy unintentionally, sporadically and spontaneously, completely  without the help of an accident. Even though airbags are designed to make drivers and passengers feel safer, in several cars the presence of an airbag  has the complete opposite effect. Airbags dashboard lights are also commonly lighting-up for no reason and without explanation. If or when the airbag on the dash board  lights-up, the system detected a problem and as a consequence sets an error code or trouble code. This implies that the airbag circuit isn't working properly and will not deploy in the event of an accident. When the airbag light comes on  for no reason, you should have your VAG car checked and  diagnosed by a trained technician because the airbag system is certainly not a D.I.Y item. There is no "reset" for an airbag system so NEVER attempt to repair it yourself since serious injury can result  if not done correctly.


Every time the ignition is switch on the system does a self check and should  it detect a problem, the air bag light is will be illuminated or flash. Repeated flashing  is actually the fail code being spelled out in a two-digit code. The light will pulse the first digit,  pause, then pulse out the second digit, pause again but for longer, then start all over again. Once the problem if fixed and the error code cleared the light will stay off.

Normally car code readers, scan tools and auto diagnostic testers omit airbag testing and interrogation unless specifically selected for fear that the diagnostic equipment or user error could trigger the airbags and cause personal injury. Numerous airbag malfunctions has occur during impact, amongst which are delayed deployment, partially deployment and complete failure to deploy. Several vehicle owners including VW, Golf  and Polo owners have complained to The National Highway Traffic and Safety Administration about airbag problems which could entitle them to a full or partial refunds for airbag problems experienced and in some cases even entitled to a new car replacement.

When a VW ends up in a crash, it stores the crash data which cannot be cleared with a VAG-COM. VW and the  airbag controller manufacturer intended it to be "unclearable" but rather replaced.  Normally the safety belts will have to be replaced along with the new airbags because the strain gauges and other electro-mechanical sensors inside them are unreliable once they have exceeded the G-forces limit at deployment.

VW POLO
Address 15:      Airbags
Controller ID No 6Q0 909 601 F
Component 05 AIRBAG VW5 0010
Coding         12341
Alternative:       12337 or 12338

00589               Airbag Igniter 1 - Passenger Side -N131
         Short to Ground  INTERMITTENT
00588        Airbag Igniter - Driver Side -N95
         Resistance to High  INTERMITTENT
00589               Airbag Igniter 1 - Passenger Side -N131
         Resistance to High  INTERMITTENT
00588           Airbag Igniter - Driver Side -N95
         Resistance to Low  INTERMITTENT
00588        Airbag Igniter - Driver Side -N95
         Short to Ground  INTERMITTENT
P1280        Passenger side Airbag Switched Off

Below is a list of airbag codings and some alternatives for those with airbag coding issues.

6Q0 909 601        -   12597 or 12622 or 12360 or 12358 or 12628 or 12344 or 12360
6Q0 909 601 A    -   12362
6Q0 909 601 C    -   12338
6Q0 909 601 E     -   12343 or 12359 or 12354 or 12338
6Q0 909 601 F     -   12341 or 12337 or 12338
6Q0 909 601 OM -   12365
6Q0 909 601 OB  -   12354
6Q0 909 601 0C   -   12355
6Q0 909 601 2A   -   12865

OTHER INTERESTING VOLKSWAGEN TOPICS
VW ABS diagnostics
VW Polo Diagnostics