mk5 gti MK60EC1 abs issue after module swop

[Shafo]

Hi friends
very first post here
my name is Shafiq and im from south Africa! I co own an auto electrical business with my dad..been running for the past 30 years..
lotsa electrical experience on vags so please don't hesitate to ask for any help from me

today however I need some serious assistance.

car is a 2009 golf 5 gti
customer initially took vehicle to a mechanic who diagnosed a faulty abs module. a brand new module was ordered via vin from VW.. mechanic fitted module and then took vehicle to VW for coding..
vw informed him that the module will not accept the basic settings and a new pump was required at a BIG cost..customer then brought vehicle to me
my current scan

VCDS Version: Release 14.10.2 (x64)
Data version: 20150311
www.Ross-Tech.com

Monday,25,May,2015,17:11:08:48700

Chassis Type: 1K (1K0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 56 62 72

VIN: AAVZZZ1KZ9U009743   Mileage: 119710km-74384miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: Malfunction 0010
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
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
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06F-907-115-AXX.lbl
   Part No SW: 1K0 907 115 R    HW: 8P0 907 115 B
   Component: 2.0l R4/4V TFSI     0020  
   Revision: 5BH16---    Serial number: VWX7Z0H73N67ZU
   Coding: 0403001018070160
   Shop #: WSC 00046 412 31414
   VCID: 356799535CFF4A898D9-8060

1 Fault Found:
005634 - Power Supply Terminal 30 
               P1602 - 002 - Voltage too Low - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 2
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 0 km
                    Time Indication: 0

             Freeze Frame:
                    RPM: 0 /min
                    Load: 0.0 %
                    Speed: 0.0 km/h
                    Temperature: -40.0°C
                    Temperature: -40.0°C
                    Absolute Pres.: 0.0 mbar
                    Voltage: 0.000 V

Readiness: 0110 0001

-------------------------------------------------------------------------------
Address 03: ABS Brakes (-----)       Labels: 1K0-907-379-60EC1F.clb
   Part No SW: 1K0 907 379 AN    HW: 1K0 907 379 AN
   Component: ESP MK60EC1   H45 0107  
   Revision: 00H45001    
   Coding: 163B600D09220003681206E8901C00813000
   Shop #: WSC 39100 001 1048576
   VCID: 7EF5467FE94949D11C3-802B

2 Faults Found:
01486 - System Function Test Activated 
            000 -  - 
             Freeze Frame:
                    Fault Status: 01100000
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 217
                    Mileage: 119713 km
                    Time Indication: 0

             Freeze Frame:
                    Count: 3
                    Count: 2
                    Count: 12800
                    Count: 320
                    Count: 43264
                    Count: 0
                    Count: 0
                    Count: 0

00003 - Control Module 
            005 - No or Incorrect Basic Setting / Adaptation
             Freeze Frame:
                    Fault Status: 01100101
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 217
                    Mileage: 119713 km
                    Time Indication: 0

             Freeze Frame:
                    Count: 3
                    Count: 2
                    Count: 12800
                    Count: 143
                    Count: 43264
                    Count: 0
                    Count: 0
                    Count: 0


-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-907-044.lbl
   Part No SW: 1K0 907 044 DE    HW: 1K0 907 044 DE
   Component: ClimatronicPQ35 130 1213  
   Revision: 00130023    Serial number: 00000000000000
   Shop #: WSC 00000 000 00000
   VCID: 6DD77133742FC249B59-8038

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3C0-937-049-30-H.lbl
   Part No SW: 3C8 937 049 E    HW: 3C8 937 049 E
   Component: Bordnetz-SG     H54 2602  
   Revision: 00H54000    Serial number: 00000008896852
   Coding: E58D8F2700041500471400001400000000097F075C000100000000000000
   Shop #: WSC 00046 412 31414
   VCID: 3363A74B528B54B9A3D-8066

   Subsystem 1 - Part No: 1K2 955 119 E  Labels: 1KX-955-119.CLB
   Component: Wischer 041108 020  0501  
   Coding: 00049109
   Shop #: WSC 00046  

   Subsystem 2 - Part No: 1K0 955 559 AF  Labels: 1K0-955-559-AF.CLB
   Component: RLS     280808 046  0204  
   Coding: 00208933
   Shop #: WSC 00046  

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 T    HW: 1K0 909 605 T
   Component: 3A AIRBAG VW8   020 2300  
   Revision: 05020000    Serial number: 0038PD260KH8  
   Coding: 0013121
   Shop #: WSC 00046 412 31414
   VCID: 3D77817364CF92C9459-8068

   Subsystem 1 - Serial number: 6332MSME3E63231AD

   Subsystem 2 - Serial number: 6342MSME375132250

   Subsystem 3 - Serial number: 6352QSME35023E38F

   Subsystem 4 - Serial number: 6362QSME4F070730E

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 BN    HW: 1K0 953 549 BN
   Component: J0527           752 0101  
   Coding: 0000042
   Shop #: WSC 00000 000 31414
   VCID: 7F0BBB7B2E4340D9175-802A

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No SW: 1K6 920 874     HW: 1K6 920 874 
   Component: KOMBIINSTRUMENT VDD 2416  
   Revision: V0002000    Serial number: VWX7Z0H73N67ZU
   Coding: 0000103
   Shop #: WSC 05147 996 88872
   VCID: 70E96847631D2FA19EF-8025

1 Fault Found:
01316 - ABS Control Module 
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 2
                    Fault Frequency: 5
                    Reset counter: 254
                    Mileage: 119707 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:00:34


-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No SW: 1K6 920 874     HW: 1K6 920 874 
   Component: KOMBIINSTRUMENT VDD 2416  
   Revision: V0002000    Serial number: VWX7Z0H73N67ZU
   Coding: 0000103
   Shop #: WSC 05147 996 88872
   VCID: 70E96847631D2FA19EF-8025

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 1K0-907-530-V3.clb
   Part No SW: 1K0 907 530 Q    HW: 1K0 907 951 
   Component: J533  Gateway   H07 5063  
   Revision:   H07 01    Serial number: 200808F1000109
   Coding: E9807F060002020003
   Shop #: WSC 00046 412 31414
   VCID: 356799535CFF4A898D9-8060

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No SW: 1K6 920 874     HW: 1K6 920 874 
   Component: IMMO            VDD 2416  
   Revision: V0002000    Serial number: VWX7Z0H73N67ZU
   Shop #: WSC 00000 000 00000
   VCID: 70E96847631D2FA19EF-8025

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MIN3.lbl
   Part No SW: 1K0 959 701 M    HW: 1K0 959 701 M
   Component: Tuer-SG         006 1210  
   Coding: 0000692
   Shop #: WSC 00046 412 31414
   VCID: 387990674BEDB7E196F-806D

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-14x-44.clb
   Part No: 1K2 909 144 M
   Component: EPS_ZFLS Kl.069 H08 1901  
   Shop #: WSC 05147 996 88872
   VCID: 36659E5F41F94191843-8063

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1K0-959-433-MAX.clb
   Part No SW: 1K0 959 433 BT    HW: 1K0 959 433 BT
   Component:    KSG PQ35 G2  020 0204  
   Revision: 00020000    Serial number: 00000000000000
   Coding: 199002005103087F2D040F0F70085FC690FC00
   Shop #: WSC 00046 412 31414
   VCID: 0303378B42AB243973D-8056

   Subsystem 1 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HORN H03 1301

   Subsystem 2 - Part No: 1K0 951 178 A
   Component: Neigungssensor  003 0203

   Subsystem 3 - Part No: 1K0 951 178 A
   Component: Innenraumueberw.003 0203

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MIN3.lbl
   Part No SW: 1K0 959 702 M    HW: 1K0 959 702 M
   Component: Tuer-SG         006 1210  
   Coding: 0000692
   Shop #: WSC 00046 412 31414
   VCID: 397F956370E7AEE9691-806C

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
   Part No: 1K0 035 186 AF
   Component: Radio GR0       036 0034  
   Revision: 0003606S    Serial number: VWZ2Z2H1224136
   Coding: 0040400
   Shop #: WSC 00046 412 31414
   VCID: 6ADD7A2F45C1D571D0B-803F

No fault code found.

-------------------------------------------------------------------------------
Address 62: Door, Rear Left        Labels: 1K0-959-703-GEN3.lbl
   Part No SW: 1K0 959 703 K    HW: 1K0 959 703 K
   Component: Tuer-SG         006 1301  
   Coding: 0000144
   Shop #: WSC 00046 412 1012566
   VCID: 387990674BEDB7E196F-806D

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right        Labels: 1K0-959-704-GEN3.lbl
   Part No SW: 1K0 959 704 K    HW: 1K0 959 704 K
   Component: Tuer-SG         006 1301  
   Coding: 0000144
   Shop #: WSC 00046 412 1012566
   VCID: 397F956370E7AEE9691-806C

No fault code found.

ive had success with EVERY basic Setting besides the Setting for Hydraulic Unit Intake Valves and disconnecting valves
I get to this point-

The control module will display the required pressure range in brackets.

If Imp. VL [116/129] >000< Press Pedal 005 is displayed, press the pedal until the actual reading is within 116 ~ 129 and maintain that pressure until [000/000] is shown.

but the issue is that it keeps asking me to input the same value..over and over. done it for over 15 minutes but the asking value only changed on 1 occasion..ive let the car cool down ive tried EVERYTHING...also I can see that the actual value is meeting the requested..
so my question is do you guys think the pump could be causing this?does it need to get out of the function test before I can do adaption?
the old modules part number- 1K0 903 379 AD

I WOULD REALLY APPRECIATE ANY HELP
thanx in advance
shafiq

 

[Jack@European_Parts]

First clear all the old faults for B+ 30 issues and correct if needed.
Verify battery fully charged.
Faulty ignition switch can cause this sporadic behavior or hold up such system tests......and inspect mini harness at switch.
Fix the COM error ( Verify CAN HIGH/LOW ) or clear it that has the same miles stamp of the scan in 0x17
NOTE
0x17 can cause all kinds of havoc for the ABS to not align proper if not seeing the VIN # through entire process.
This is why if you remove and then restart coding goes to zero...... or when someone does a miles recalibration.
Poor ground?

 

[Shafo]

So i did do a complete dtc clear before posting this and its odd that its showing a fault code in instruments yet this - 17-Instruments -- Status: OK 0000
I must admit it didnt grab my attention because of that..will try and sort that tomorrow.
Another odd thing.ive been reading about people saying the long coding reverts back to zero when removing the module but i actually unplugged the new module and put the old one in to see what the long coding was. I then copied the code and fitted the new module back in..i pasted the code and it basically told me the current code was the same..the code DID NOT revert back to zero..odd...anyway
Il try to get rid of the cluster fault and redo the adaption...
Also, i didnt see for myself, but client claims with original module in he would clear all faults and abs light would go off.he would then ride for like 15 min and abs light would reappear (fault was something to do with abs module being faulty) hence them replacing the module..
Ive double checked the earths and supplies
will post back with my results tomorrow

 

[Jack@European_Parts]

So i did do a complete dtc clear before posting this and its odd that its showing a fault code in instruments yet this - 17-Instruments -- Status: OK 0000
I must admit it didnt grab my attention because of that..will try and sort that tomorrow.
Another odd thing.ive been reading about people saying the long coding reverts back to zero when removing the module but i actually unplugged the new module and put the old one in to see what the long coding was. I then copied the code and fitted the new module back in..i pasted the code and it basically told me the current code was the same..the code DID NOT revert back to zero..odd...anyway
Il try to get rid of the cluster fault and redo the adaption...
Also, i didnt see for myself, but client claims with original module in he would clear all faults and abs light would go off.he would then ride for like 15 min and abs light would reappear (fault was something to do with abs module being faulty) hence them replacing the module..
Ive double checked the earths and supplies
will post back with my results tomorrow

It's when the cluster loses power or is disconnected while the ABS has been hot or switched that causes a reset of zeros.
Can also happen from blown fuse or when someone removes CAN twisted pair HIGH/LOW tracks at box, while battery is hot and key on.

 

[GaryM]

If you see a "Status: OK 0000" in the installation list for any control modules but under the detailed scan for any of those control modules it is showing fault codes, try doing a DTC reset for each of those individual control modules rather than using the global DTC reset in the Auto-Scan screen. When you then next do a full Auto-Scan, the fault code status you see in the installation list should then be re-sync'd with what you see in the detailed scan items.

 

[Shafo]

hi again friends. i reset all error codes individually .. all errors are now gone besides the two faults in the abs module..
I checked the abs wiring again and all is fine..i have no comms issues at all..
my basic settings on the abs valves just doesn't work....
anything else I could try?
is it possible that the error code of the FUNCTION TEST BEING ACTIVE could cause this?

 

[NEtech]

If Imp. VL [116/129] >000< Press Pedal 005 is displayed, press the pedal until the actual reading is within 116 ~ 129 and maintain that pressure until [000/000] is shown.
but the issue is that it keeps asking me to input the same value..over and over.

Have you checked brake switch and pressure function in MWB (Engine and ABS)?
Try and explain how you do it.
- Engine running
- Outside temp. 10.0...60.0 C
- Placed in driver seat with tester
- Login
- Basic settings MWB 025
- Press [ON/OFF/Next]
When you press the brake pedal, does the pressure increase in >xxx< up to eg. 120 ?, is it then showing >000< ? or is that the problem ?

I would also think the Valves basic settings has to be performed first,
But yes you can try and do the function test driving procedure.

Maybe you have to make the drive test after a successful basic setting MWB 025 and then do the basic setting on MWB 026.

 

[Shafo]

Have you checked brake switch and pressure function in MWB (Engine and ABS)?
Try and explain how you do it.
- Engine running
- Outside temp. 10.0...60.0 C
- Placed in driver seat with tester
- Login
- Basic settings MWB 025
- Press [ON/OFF/Next]
When you press the brake pedal, does the pressure increase in >xxx< up to eg. 120 ?, is it then showing >000< ? or is that the problem ?

I would also think the Valves basic settings has to be performed first,
But yes you can try and do the function test driving procedure.

Maybe you have to make the drive test after a successful basic setting MWB 025 and then do the basic setting on MWB 026.

my procedure is EXACTLY as you stated above...and YES my pressure increases perfectly..i get the actual pressure to the requested and the pedal drops and I feel the click...the value then shows 0..i leave the pedal...issue is that it keeps requesting the same pressure value over and over..it did change the request value on a few occasions but only once or twice then the same thing...request same value..
im at a loss

oh and brake light switch is fine..

 

[Shafo]

I don't know if its worth mentioning but the mechanic who helped me bleed the system, he bled the normal way without using vcds..is that ok?

 

[NEtech]

What is the part number for installed hydraulic unit ?

 

[Shafo]

1k0 614 517 BD

 

[Jack@European_Parts]

I don't know if its worth mentioning but the mechanic who helped me bleed the system, he bled the normal way without using vcds..is that ok?

In my experience if bleeding conventionally with ABS........... it is always advised to do it with engine running so the ABS pump engages its PSI cycle on its own.

We had systems that were not able to have a scanner in 1989 and the only way we could get to bleed without a soft pedal was to do this way.

I don't think that is the case here.

Did you double check the part # is correct for the VIN at dealer......... just in case a mistake was made?

 

[Shafo]

I did contact parts guy and he claims its fine

Original part- 1K0 907 379 AD
New part- 1K0 907 379 AN

Im going insane with this fault

 

[Jack@European_Parts]

I show the part # should be 1K0-907-375AN not 379AN ,however,...... it should still work since even this # will backward supersede.

I would clear DTC's in 0x44 and recode + readapt steering module there first........ then go to ABS 0x03 and try again after recoding doing the ADP test via logins.........one by one.

Be sure to do these tests with engine idling and all during same session..

 

[Spacewalker]

I show the part # should be 1K0-907-375AN not 379AN ,h.

375 is not a replacemenet part for sale ? , 379 is a 1st build genuine in manufacture
Like with a cluster xxxxxx870A is a build in manufacture, xxxxxx870AX is a replacemenet for sale

 

[Shafo]

Thanks for that Jack! Will give it a shot in the morning and report back here!

 

[Airmec]

For whats its worth I had a similar problem with a Passat, even the power steering went down. From memory I carried out the basic settings then drove the car steering left to right, all the warning lights then cancelled out and everything was ok.

 

[Jack@European_Parts]

375 is not a replacemenet part for sale ? , 379 is a 1st build genuine in manufacture
Like with a cluster xxxxxx870A is a build in manufacture, xxxxxx870AX is a replacemenet for sale

Respectfully incorrect Space Ace.
The Etka reflects what I state.

 

[Shafo]

Done all basic settings again...all in one session...still no luck

 

[Jack@European_Parts]

Explain each test one at a time and are each test passing?
Maybe missing a test?