Pauls Polo 6R Trendline conversion road to OEM++

[Paulpelz]

Now here the promised pictures:

My extremely helpful colleague, happily standing in my completely stripped out engine bay:

Jemand im Motorraum.jpg (773.85 KiB) Viewed 782 times

And my kind of finished looking engine bay about three hours later (ignore the crooked wiper ):

Eingebauter Motor bearbeitet.jpg (1.04 MiB) Viewed 782 times

Things left to do: driveshafts (yes I know I should have done it right after putting the engine in), AC compressor, alternator, belt, exhaust system, starter. In other words: Just a few hours of work left and I might hear my car come back to live after more than half a year

[iichel]

if you're using the same instrument cluster and key, probably only need to code the abs controller

Does this even apply if the ECU and the engine are not from the same donor car?

the ecu doesn't care where the engine is from, as long as it's the correct engine code. immo is a triangle of ecu, cluster and key. abs needs all VINs to match.

[Paulpelz]

Update number 29401ß0348?
It runs! And pretty good actually! I am absolutely over the moon and have a massive smile on my face since the time I twisted the keys.

Now the annoying bits: Ironing out all the little remaining faults:
- Basic setting of the steering angle sensor. I had this problem some months ago, so this shoudn't be a big one.
- Disassembling and rebuilding the back axle because I screwed up and mounted the shieldplate underneath the axle stump.
- Fixing the exhaust, since it is leaky AND banging on the chassis.

Also, there are some faults I cannot make sense of, so I hope you all can:
1. When the engine is running (and only then) I have the following fault codes (please excuse my use of OBD11, my VCDS-laptop is broken-ish):

P11AB00 - Cam Shift Actuator "B" Cylinder 3 Circuit/Open
static
P11A700 - Cam Shift Actuator "B" Cylinder 2 Circuit/Open
static
P31AB00 - Cam Shift Actuator Outlet "B" Cylinder 3 Circuit Low
static
P31AA00 - Cam Shift Actuator Outlet "B" Cylinder 2 Circuit Low
static
P11A900 - Cam Shift Actuator "A" Cylinder 3 Circuit/Open
static
P11A500 - Cam Shift Actuator "A" Cylinder 2 Circuit/Open
static
P31BB00 - Cam Shift Actuator Outlet "A" Cylinder 3 Circuit Low
static
P31BA00 - Cam Shift Actuator Outlet "A" Cylinder 2 Circuit Low
static
P11C100 - Cam Shift Actuator Outlet "A" Cylinder 2 Range/Performance
static

Of course all four actuators could be broken at once but I don't really think so. Do they have to get learned to the ECU or is there something else I am missing, maybe some adress-19-shenanigans?

2. Adress 08: Air conditioning:
I mentioned it previously, but here is the situation again: The Polo 6R Blue GT doesn't have a coolant fan relay. The fan has the relay built into the hub and gets triggered by the ECU, so there are only four wires going into the fan. So far so good. But "normal" Polos have two additional wires from the Climatronic/Climatic/Manual Unit to the fan relay, triggering the fan if A/C is activated. These two wires are now unconnected on the fan side of my Polo, which unsurprisingly gets moaned about by the Climatronic unit. Is there a way to make it shut up about this and (probably) use the CAN network to call for the fan?

[iichel]

change some adaptation channels in 08 hvac to fix the fan issues

image0.jpeg (127.37 KiB) Viewed 645 times

[Paulpelz]

Thanks! That has got to be it!
Sadly, there are no labels in VCDS for the adaption channels, so I just guessed and changed the following:
Ch 1: 0 -> 1
Ch 2: 0 -> 1 (I installed one of these coombined rain and moisture sensors ages ago together with my high beam assist conversion)
Ch 3: 1 -> 0
Ch 4: I don't know the value, but I haven't changed it
Ch 5-7: 0 -> 1

Now it stopped moaning about the missing wires, but instead started infoming me about being coded wrong. So there is still some experimenting left to do. But thanks Michel, without your picture i would never have been able to fix that issue.

[Paulpelz]

Also, there are some faults I cannot make sense of, so I hope you all can:
1. When the engine is running (and only then) I have the following fault codes (please excuse my use of OBD11, my VCDS-laptop is broken-ish):

P11AB00 - Cam Shift Actuator "B" Cylinder 3 Circuit/Open
static
P11A700 - Cam Shift Actuator "B" Cylinder 2 Circuit/Open
static
P31AB00 - Cam Shift Actuator Outlet "B" Cylinder 3 Circuit Low
static
P31AA00 - Cam Shift Actuator Outlet "B" Cylinder 2 Circuit Low
static
P11A900 - Cam Shift Actuator "A" Cylinder 3 Circuit/Open
static
P11A500 - Cam Shift Actuator "A" Cylinder 2 Circuit/Open
static
P31BB00 - Cam Shift Actuator Outlet "A" Cylinder 3 Circuit Low
static
P31BA00 - Cam Shift Actuator Outlet "A" Cylinder 2 Circuit Low
static
P11C100 - Cam Shift Actuator Outlet "A" Cylinder 2 Range/Performance
static

Of course all four actuators could be broken at once but I don't really think so. Do they have to get learned to the ECU or is there something else I am missing, maybe some adress-19-shenanigans?

Here I found my issue: I accidentially swapped the Pins 5 and 6 in the connector between engine harness and central harness. Swapping those into their proper positions resolved my issues. Now my engine is running like a charm and there are only some minor sporadic faults stored.

[iichel]

I guess it's time to change your signature then. Well done, keep it posted.

[Paulpelz]

You are absolutely right, thanks for reminding me!

Now one of the only remaining things to rectify before I can bring my car to its technical inspection is to get the start-stop system working.
As of now, everytime I start the car, the instrument cluster tells me "Fault: Start-Stop". The button in the center console also does nothing.
I suspect I only have to tick some boxes in the coding of some control units or have to fiddle around with some adaption channels to get it to work. Does anyone know which control units have something to do with the start-stop functionality?
I will later post an updated Autoscan.

Also, just for completeness: I didn't yet code my ABS system for the new engine. I assume this might have something to do with the problem. I will try some codings later today, so maybe this entire post was a complete waste of time

[Paulpelz]

Well, looks very much like a waste of time it was...
Since I fiddled around with the ABS coding a little bit, start-stop miraculously started working. Funny enough however: My deactivation button does not work. As pointed out in one of my previous posts, the wiring diagram is just wrong concerning that matter, so I have to keep trying. How hard could it be?! Famous last words...

On a side note, below is a current autoscan from earlier today(ish).

Code: Select all

Saturday,25,May,2024,14:38:53:44001
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 11 x64
VCDS Version: 24.5.0.0 (x64)
Data version: 20240429 DS355.0
www.Ross-Tech.com


VIN: WVWZZZ6RZCY154963   License Plate: 
Mileage: 130620km-81163mi   Repair Order: 



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 6R-VW25 (7E0)
Scan: 01 03 04 08 09 10 15 17 19 20 25 37 44 47 55 5F 61

VIN: WVWZZZ6RZCY154963   Mileage: 130620km-81163miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: OK 0000
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
20-High Beam Assist. -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
37-Navigation -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
47-Sound System -- Status: Malfunction 0010
55-Headlight Range -- Status: OK 0000
5F-Information Electr. -- Status: Malfunction 0010
61-Battery Regul. -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine (J623-CPTA)       Labels:. 04E-907-309-V1.clb
   Part No SW: 04E 906 016 Q    HW: 04E 907 309 D
   Component: 1.4l R4 TSI   H08 7599  
   Revision: WCH08---    Serial number:                CVN: CFB85C3E
   Coding: 00190032242411000000
   Shop #: WSC 92521 052 00000
   ASAM Dataset: EV_ECM14TFS01104E906016Q 002011
   ROD: EV_ECM14TFS01104E906016Q_002.rod
   VCID: 306898F86B88B216F3-8064
   VINID: 9E69EAAAA1A2A93A411442460C9D751C47

1 Fault Found:
5583 - Oil Pressure Switch for reduced Oil Pressure 
          P164C 00 [01100000] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 130623 km
                    Date: 2024.05.24
                    Time: 23:35:56

                    Engine RPM: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 88 °C
                    Intake air temperature: 44 °C
                    Ambient air pressure: 1010 mbar
                    Voltage terminal 30: 12.604 V
                    Unlearning counter according OBD: 40
                    Mass flow through throttle valve: 2.6 kg/h
                    Mean injection time: 0.797 ms
                    Engine operating condition: Idle
                    Engine operating condition-Test_Program_Channel 87: 5
                    A/C compressor: load current: act. value: 152.50 A

Readiness: 0110 0001

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 6R0-907-37x-ESP90.clb
   Part No SW: 6R0 907 379 AS    HW: 6R0 907 379 AS
   Component: ESP9.0i front H02 0002  
   Serial number: --------------
   Coding: 21DD4885232800C4841D126FC45400550904
   Shop #: WSC 01383 785 00200
   ASAM Dataset: EV_Brake1ESP90iBOSCH 003020
   ROD: EV_Brake1ESP90iBOSCH_VW25.rod
   VCID: 0F2A3B04D6F68DEECA-805A

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels: 6R0-907-044.clb
   Part No SW: 6R0 907 044 H    HW: 6R0 907 044 H
   Component: Climatronic   H12 0812  
   Revision: V0000000    
   VCID: 3878A0D88BF86A56BB-806C

1 Fault Found:
00229 - Refrigerant Pressure 
            002 - Lower Limit Exceeded
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 13
                    Mileage: 130618 km
                    Time Indication: 0
                    Date: 2024.05.21
                    Time: 04:24:49


-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 7E0-937-BCM-V1.clb
   Part No SW: 7E0 937 090 C    HW: 7E0 937 090 C
   Component: BCM PQ25 Max4 H82 0752  
   Revision: B9082001    Serial number: 4000 259171299
   Coding: 3CB02BBF4821000021380FE06EEB9FD1C6C067CF608D7850210000030800
   Shop #: WSC 12345 123 61029
   VCID: 2B528F944AAED1CEC6-807E

   Subsystem 1 - Part No: 5K7 955 547 
   Component: RLHS 200618 0  50  0107 
   Coding: 008F77

   Subsystem 2 - Part No SW: 6R0 959 801 DJ    HW: 6R0 959 801 DJ  Labels: 6R0-959-801.CLB
   Component: J386__TSG_FT  004 0610 
   Serial number: KU0KU021031770802804
   Coding: 0200A3

   Subsystem 3 - Part No SW: 6R0 959 802 DN    HW: 6R0 959 802 DN  Labels: 6R0-959-802.CLB
   Component: J387__TSG_BT  003 0610 
   Serial number: KU0KU005081662186418
   Coding: 1000AB

   Subsystem 5 - Part No SW: 6R0 959 811 G    HW: 6R0 959 811 G
   Component: J388__TSG_HL  008 1611 
   Serial number: KU0KU011111100010576
   Coding: 08BC32

   Subsystem 6 - Part No SW: 6R0 959 812 G    HW: 6R0 959 812 G
   Component: J389__TSG_HR  008 1611 
   Serial number: KU0KU014111100016138
   Coding: 08BC32

No fault code found.

-------------------------------------------------------------------------------
Address 10: Park/Steer Assist (J446)       Labels:| 7E0-919-475.clb
   Part No SW: 7E0 919 475 AA    HW: 7N0 919 475 
   Component: PARKHILFE 8K  H06 0212  
   Revision: --------    Serial number: 28231921103426
   Coding: 308009
   Shop #: WSC 12345 123 61029
   ASAM Dataset: EV_VW75XParkAssis8K 001012
   ROD: EV_EPHVA18VW250GPCS_VW25.rod
   VCID: 71EE5DFCA002FB1EBC-8024

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 6R0 959 655 K    HW: 6R0 959 655 K
   Component: VW10Airbag01M H09 0020  
   Revision: --------    Serial number: 003GX0108L3% Dataset Number: v00305696R0 0001
   Coding: 00314D
   Shop #: WSC 00788 648 00255
   ASAM Dataset: EV_AirbaVW10BPAVW250 A01001
   ROD: EV_AirbaVW10BPAVW250.rod
   VCID: 4A9CEA10ED14E8C6DD-801E

   Crash sensor for side airbag: driver side: 
   Serial number: 3575HRB405R0UJCIB1I5

   Front Passenger's Side Airbag Crash Sensor: 
   Serial number: 3585HRB405F0UJCI4H6Y

   Rear Side Airbag Crash Sensor (on driver's side): 
   Serial number: 3515RRB40650TGJKB0CT

   Passenger side rear thorax airbag crash sensor: 
   Serial number: 3525RRB40610UT98K0GV

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 6R0 920 870 D    HW: 6R0 920 870 D
   Component: KOMBI         H04 0709  
   Serial number: 00000000000000
   Coding: 140E00
   Shop #: WSC 12345 123 61029
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04723
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW25.rod
   VCID: 3664AEE089EC9C26A9-8062

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7E0-909-901.clb
   Part No SW: 7E0 909 901     HW: 7E0 937 090 C
   Component: GW-K-CAN TP20 H82 0752  
   Revision: B9082001    
   Coding: 002201
   Shop #: WSC 12345 123 61029
   VCID: 68D830989BD83AD6EB-803C

No fault code found.

-------------------------------------------------------------------------------
Address 20: High Beam Assist. (J844)       Labels:. 8S0-857-511.clb
   Part No SW: 7E0 857 511 F    HW: 7E0 857 511 C
   Component: FLA           H10 0003  
   Revision: AA001001    
   Coding: 0404000000000000010000
   Shop #: WSC 02739 790 50316
   ASAM Dataset: EV_HighBeamAssisAU316 001004
   ROD: N/A
   VCID: 2D56818C7CBADFFED8-8078

No ASAM data for: "EV_HighBeamAssisAU316" (VW25) 
No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234 
   Component: IMMO          H04 0709  
   Serial number:               
   Coding: 000000
   Shop #: WSC 09402 015 1048576
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03710
   ROD: EV_Immo_UDS_VDD_RM09_VW25.rod
   VCID: 6ADC4A908DD408C6FD-803E

No fault code found.

-------------------------------------------------------------------------------
Address 37: Navigation
Cannot be reached

-------------------------------------------------------------------------------
Address 44: Steering Assist (J792)       Labels:| 6Rx-909-144-V2.clb
   Part No SW: 6R1 909 144 AJ    HW: 6R1 909 144 E
   Component: EPS_TRW_ALow  312 3132  
   Serial number: CF8D0787 Dataset Number: 8XA909852D  0019
   Coding: 000300
   Shop #: WSC 00046 412 54321
   ASAM Dataset: EV_SteerAssisUDSTRW 016029
   ROD: EV_SteerAssisUDSTRW.rod
   VCID: 7F0A8BC4E6569D6E3A-802A

No fault code found.

-------------------------------------------------------------------------------
Address 47: Sound System (R12)       Labels: 5K0-035-456.clb
   Part No SW: 5C6 035 456 C    HW: 5C6 035 456 C
   Component: KonzernAmp10K H08 6831  
   Revision: --------    Serial number: EAA098C0000022 Dataset Number: 0001
   ASAM Dataset: EV_AudioVerst10KanalSTT4 001001
   ROD: EV_AudioVerst10KanalSTT4_VW36.rod
   VCID: 285870985358FAD62B-807C

2 Faults Found:
9462035 - Front Left Treble Speaker 
          B1061 13 [00001001] - Open Circuit
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 12
                    Mileage: 130617 km
                    Date: 2024.05.21
                    Time: 00:01:33

9462803 - Front Right Treble Speaker 
          B1064 13 [00001001] - Open Circuit
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 12
                    Mileage: 130617 km
                    Date: 2024.05.21
                    Time: 00:01:33


-------------------------------------------------------------------------------
Address 55: Headlight Range (J431)       Labels:. 6R0-907-357.clb
   Part No SW: 6R0 907 357     HW: 6R0 907 357 
   Component: LWR-ECU       H02 0070  
   Revision: --------    Serial number: -------------- Dataset Number: 6R0036v____ 0005
   Coding: 011A000001000000
   Shop #: WSC 00788 648 00255
   ASAM Dataset: EV_HeadlRegulVWLWRPt 001004
   ROD: EV_HeadlRegulVWLWRPt_VW25.rod
   VCID: 77FA63E4CE66A52E72-8022

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels:| 5G0-035-MIB-STD2.clb
   Part No SW: 5C0 035 680 G    HW: 5C0 035 680 G
   Component: MU-S-ND-ER    H41 0478  
   Serial number: VWZAZ2U0997762 Dataset Number: V03935266VJ 0001
   Coding: 02620001AA00000011111103C00D0A201F0110D400200100CE
   Shop #: WSC 00012 790 50316
   ASAM Dataset: EV_MUStd4CTSAT 001022
   ROD: EV_MUStd4CTSAT_VW37.rod
   VCID: 254679AC244AE7BE10-8070

   Data carrier: 
   Subsystem 1 - Part No SW: 5NA 919 866 BK    HW: -----------
   Component: ECE AS 2022  --- 1720 
   Serial number: --------------------

3 Faults Found:
1555 - Check Software Version Management 
          B201A 00 [00001001] - -
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 15
                    Mileage: 130620 km
                    Date: 2024.05.23
                    Time: 20:42:15

                    Voltage terminal 30: 12.4 V
                    Status_Software_Version_Management-module_name: 

1556 - Internal Control Module Memory Check Sum Error 
          B2000 87 [00001001] - Missing Message
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 15
                    Mileage: 130620 km
                    Date: 2024.05.23
                    Time: 20:45:13

                    Voltage terminal 30: 12.5 V
                    System_Software_Error-SW_Status_Consistency: 04 01 01
                    System_Software_Error-SW_Status_Device: o

15360256 - Component Protection 
          U1101 00 [00001001] - Active
          [New feature! Extended UDS fault detail is only supported by current gen. interfaces]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Priority: 4
                    Fault Frequency: 1
                    Reset counter: 15
                    Mileage: 130620 km
                    Date: 2024.05.23
                    Time: 20:42:15

                    Voltage terminal 30: 12.4 V


-------------------------------------------------------------------------------
Address 61: Battery Regul. (J840)       Labels:. 1K0-907-534.clb
   Part No SW: 7E0 907 534     HW: 7E0 937 090 C
   Component: Batt.regelung H82 0752  
   Serial number: 4000 259171299
   Coding: 032B7A64
   Shop #: WSC 12345 123 12345
   VCID: 68D830989BD83AD6EB-803C

   Subsystem 1 - Part No SW: 6R0 915 181 E    HW: 6R0 915 181 E
   Component: J367-BDM  H08 0181 
   Serial number: 50231J15312031943146

No fault code found.

End-------------------------(Elapsed Time: 03:36)--------------------------

The oil pressure switch is probably just faulty, so I'll fire the parts cannon at it. The part is cheap and I don't feel like checking wires.
The HVAC fault is expected, since I haven't filled the AC system back up yet.
The sound system is indeed missing the two treble speakers, I have to repair the bloody A-pillar-covers... again.
And the MIB-PQ unit is complaining about that stuff since I installed it, but is working absolutely flawless. So whatever.

All in all: I am almost done. Incredible...

[Paulpelz]

A few days later, and nothing changed. Well, that's not completely true. I fixed a knocking in the steering assembly (it turned out we forgot to tighten the nuts of the tie rod ends... whoops ), also I installed the underbody covers and fiddled a bit with the exhaust, so that it doesn't touch the heatshields anymore. Though I am still not completely satisfied with the result as the tips don't sit absolutely perfectly in the middle of the bumper cutout... that's a later problem.
Concerning the start-stop-button I still haven't found the solution. Start-Stop itself is working on the other hand, so I might just procrastinate on that problem a little bit. For the technical inspection it just has to work at all.
Now my question for the day: Is there a possibility to test the 2-Cylinder-Mode on the car? I mean: other than to actually drive and accidentially stumble across the narrow area where it will switch the two cylinders off? Maybe a VCDS readout or something? Because I don't know if my instrument cluster will display the message, since it is out of a Toledo...

[Paulpelz]

Concerning the start-stop-button I still haven't found the solution. Start-Stop itself is working on the other hand, so I might just procrastinate on that problem a little bit. For the technical inspection it just has to work at all.

Wrong. I couldn't leave it alone. And it turns out I'm an idiot.
I wired negative cables to two pins that should have +12 volts. I have absolutely no idea how I f*cked this up. I'll fix it tomorrow and report again!