US MK4 Jetta Upgraded to 4Motion

   #1  

manicslothpdx

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My US 2004 Jetta TDI has been converted to 4Motion. During the project, we also installed an R32 steering rack. I did a ton of research in advance, so I am 99% confident all of the parts we installed are compatible. However, we are having issues with the R32 ABS module we installed. I should mentioned right up front that it was a used module. I should also mention that this post won't have a VCDS log, but I will be able to provide one in a followup post. I am coordinating with my mechanic but we're in different cities. He should be sending me a VCDS log any time now.

Here is the info he sent me earlier. The short version is that with my original ABS module, we can run all the Haldex tests, but with the R32 module, we can't communicate with it or the Haldex. In neither scenario, however, with 4Motion work yet:

With the ABS module installed that you sent me, the car throws a bunch of fault codes. ESP defective, Steering angle no basic settings, incorrect coding, & AWD no communication. I believe that the ABS module is bad due to the ESP Sensor Unit Defective fault code. With this ABS module installed AWD is not working while driving the car. I can get the front wheels to spin in 1st gear. I plugged your original ABS module in to test and I have ZERO fault codes. However, AWD still doesn't work. I can however communicate with the AWD module, scan for faults, perform output tests, etc. I can activate the Haldex pump, etc. The AWD module does throw fault codes for no communication with ECU and no communication with ABS. My car still to this day throws those fault codes in the AWD module, however my AWD works without any issues.

So I am thinking that we might need a correct ABS module that is actually working.

I will say that the coding for the ABS module looks funky. I am not sure how it got to 23049 because if you look at all of the coding options the largest number you can add up to is like 19081. Any attempt to change coding in the ABS module results in a request out of range message. I also cannot log in to security access. Ross Tech Wiki states the security access code should be 40168, but it will not accept that.

My mechanic performed a similar conversion in his GTI, which is why he references his car.

I will post VCDS log later this evening. Thanks in advance for any assistant.
 
   #2  

manicslothpdx

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One thing I do know is we need to perform the steering wheel angle sensor procedure. I tried posting an image via Dropbox, but it didn't seem to work.

According to my research, the MK60 ABS module should work in my car without wiring modifications.

I also made sure to get the appropriate rear ABS sensors.
 
   #3  

manicslothpdx

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While I wait for my mechanic to upload the VCDS log, I will manually type in the codes that are currently being displayed when the 4Motion ABS module is installed:

01044 - Control Module Incorrectly Coded
000--

00493 - ESP Sensor Unit (G419)
014 - Defective

00778 - Steering Angle Sensor (G85)
005 - No or Incorrect Basic Setting / Adaptation

01324 - Control Module for All Wheel Drive (J492)
004 - No Signal/Communication

All of them go away if the original ABS module is re-installed and the codes are cleared.
 
   #4  

Jetta 97

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Is your Jetta has MFSW ?
If not you do not have G85, That will be one of the problems. But I think also R32 ABS is bad .
 
   #5  

manicslothpdx

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I don't have a multi-function steering wheel. I do have a steering angle sensor, but we haven't re-calibrated it yet.

I have been spending the last 45 minutes cross referencing all the invidual error codes on the the Ross-Tech site. Could most of these errors be because we need to finish the steering angle sensor re-calibration process?
 
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   #7  

manicslothpdx

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My mechanic left for the day. I will post it ASAP tomorrow morning.
 
   #8  

manicslothpdx

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Code:
Tuesday,22,March,2022,15:37:06:49772
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 22.3.0.1 (x64)  HEX-NET CB: 0.4613.4
Data version: 20220225 DS336.1
www.Ross-Tech.com


VIN: 3VWSR69M34M106546   License Plate:


Chassis Type: 9M (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
          76
 
VIN: 3VWSR69M34M106546   Mileage: 300260km-186572miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-016-BEW.lbl
   Part No SW: 038 997 016 L    HW: 028 101 114 6
   Component: R4 1,9L EDC G000SG  3791 
   Revision: 12345678    Serial number: VWZ7Z0D9018356
   Coding: 0150031
   Shop #: WSC 01838 256 00064
   VCID: 271EFEB6972F78B7A3-5184
   VINID: 0E69E388625D0C474100614418462124DC

No fault code found.
Readiness: 0 0 1 1 1

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ESP-A.lbl
   Part No: 1C0 907 379 P
   Component: ESP ALLRAD MK60     0101 
   Coding: 0023049
   Shop #: WSC 31414 000 00000
   VCID: 373E2EF6478FE83733-5184

3 Faults Found:
00493 - ESP-Sensor Unit (G419)
            014 - Defective
01044 - Control Module Incorrectly Coded
            000 - -
01324 - Control Module for All Wheel Drive (J492)
            004 - No Signal/Communication

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl
   Part No: 3B1 907 044 C
   Component: CLIMATRONIC     C 2.0.0 
   Coding: 11200
   Shop #: WSC 31414 
   VCID: 210AE0AEA90B8687ED-51A8

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 F
   Component: 04 AIRBAG VW61 0202 0003 
   Coding: 12340
   Shop #: WSC 00066 
   VCID: 271EFEB6C72F78B7A3-513C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J5 920 946 C
   Component: KOMBI+WEGFAHRSP VDO V20 
   Coding: 15232
   Shop #: WSC 00050 
   VCID: 312A10EEF9EB36077D-513C

   Subsystem 1 - Part No: Clusters
   Component: By Litke     VWZ7Z0D9018356 
   Clusters By Litke     VWZ7Z0D9018356

1 Fault Found:
01335 - Drivers Seat/Mirror Position Control Module (J543)
            49-00 - No Communications

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.clb
   Part No: 6N0 909 901
   Component: Gateway K<->CAN    0001 
   Coding: 00006
   Shop #: WSC 01266 
   VCID: 70ACD5EA32617F0F32-513C

1 Fault Found:
01335 - Drivers Seat/Mirror Position Control Module (J543)
            49-00 - No Communications

-------------------------------------------------------------------------------
Address 22: AWD        Labels: 02D-900-554.lbl
   Part No: 02D 900 554 C
   Component: HALDEX LSC  ECC     0009 
   VCID: 200CE5AAA2018F8FE2-4B3C

2 Faults Found:
01316 - ABS Control Module
            49-10 - No Communications - Intermittent
01314 - Engine Control Module
            49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 29: Left Light        Labels: 7M3-907-391-29.lbl
   Part No: 7M3 907 391
   Component: EVG GDL + AutoLWR   0003 
   Coding: 00003
   Shop #: WSC 00000 
   VCID: 74A4D9FA4679432FD6-4B9A

2 Faults Found:
00496 - Sensor for Vehicle Leveling; Front
            07-00 - Signal too Low
00497 - Sensor for Vehicle Leveling; Rear
            07-00 - Signal too Low

-------------------------------------------------------------------------------
Address 39: Right Light        Labels: 7M3-907-391-39.lbl
   Part No: 7M3 907 391
   Component: EVG GDL + AutoLWR   0003 
   Coding: 00003
   Shop #: WSC 00000 
   VCID: 74A4D9FA4679432FD6-4BBA

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 C
   Component: 1H Komfortgerát HLO 0003 
   Coding: 00259
   Shop #: WSC 00222 
   VCID: 373E2EF6178FE83733-4B1E

   Subsystem 1 - Part No: 1C0959801B
   Component: 17 Tõrsteuer.FS KLO 0202 

   Subsystem 2 - Part No: 1C0959802C
   Component: 17 Tõrsteuer.BF KLO 0202 

   Subsystem 3 - Part No: 1C0959811A
   Component: 1H Tõrsteuer.HL KLO 0202 

   Subsystem 4 - Part No: 1C0959812A
   Component: 1H Tõrsteuer.HR KLO 0202 

No fault code found.

-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: 1J0-919-283.lbl
   Part No: 1J0 919 283 A
   Component: Einparkhilfe        0001 
   Coding: 00113
   Shop #: WSC 01266 
   VCID: 2C14019ADEC95BEF4E-513C

No fault code found.

End----(Elapsed Time: 04:22, VBatt start/end: 12.2V/11.9V. VIgn 11.6V)-----
 
   #9  

manicslothpdx

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And, here is the update from my mechanic:

Ok so I was able to make a bit of progress. For whatever reason I was entering the 40168 into the security access code when I needed to be putting it into coding 2. I was able to do that, however when I followed the steps for the steering angle calibration, I got to basic setting 60 - Go - On/Off/Next. When I hit on/off/next everything just errors out. Well now the car no longer throws the no basic settings fault code but still has the ESP defective, No comms with AWD, and control module incorrectly coded.
 
   #10  

manicslothpdx

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One thing I just learned, that I hadn't seen in many of the other forum threads I had read, is that there are two versions of the G419 sensor.

The front wheel drive version has two sensors: lateral acceleration and yaw
The 4Motion version has three sensors: lateral acceleration, yaw and longitudinal acceleration

In my car currently is the FWD version. I just ordered the 4Motion version.

Could this be an issue of the ABS module needing to be paired with the correct G419 sensor?

I have an 4Motion/R32 ABS module: 1C0907379P
We're ordering the 4Motion G419 sensor: 1J1907638F
 
   #11  

manicslothpdx

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I learned a few things since I started this post, but I am hoping I might be able to get verification.

I have the appropriate 4Motion ABS module but I definitely need the 4Motion version of the G419 sensor. This is almost certainly why attempts to calibrate it fail.

The coding of 23049 should be correct for my setup. A regular VW forum user Graeme mentioned that the Ross-Tech doc for calculating this might have two of the coding options backwards.

ross-tech have the coding reversed further up page:
Engine II
+0001024 = Drive-By-Wire Engines this coding is backwards - should be "Cable-Throttle Engines"
+0004096 = Cable-Throttle Engines >>>>>>>>>>>>>>>>>>> - should be "Drive-By-Wire Engines"

If I do that math knowing that, then the numbers match.

I will also need to perform an addition calibration process that involves driving in a figure 8 once the coding is correct.

Does this sound correct, and am I missing anything major?

Thanks.
 
   #12  

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One thing I just learned, that I hadn't seen in many of the other forum threads I had read, is that there are two versions of the G419 sensor.
Yes, I had to fit the ESP sensor for a 4motion in my MK5 based car. It's external to the ABS, so easy to do. In the MK5 it's a straight swap... BUT is mounted is a different orientation in my car (I have MK5 4motion fitted to my Touran 7 seater).

You can't do the basic settings without the correct sensor.
 
   #13  

manicslothpdx

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I can report some progress, but we are still getting errors. The 3-sensor version of the G419 sensor arrived. Here is the reply from my mechanic:

"I also got the new ESP module installed. We are no longer throwing the ESP sensor unit defective fault code. So that is good. However we do still have ABS lights on the dash, flashing brake light, and fault codes for ABS module incorrectly coded. See attached photos for reference and let me know what you think we should do next."

It appears to be accepting coding now, but VCDS still shows the error "Control Module Incorrectly Coded." I was previously confident in the coding we were using of "0023049" because it was recommended by a well know forum user named Graeme who has been helping me too via email. He explained all the math to me as well re how he came to that number.

Here is a new VCDS log. I will try and post some VCDS screenshot too, if I can figure out why Dropbox links aren't working for me:


Code:
Wednesday,06,April,2022,09:48:09:49772
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 22.3.0.1 (x64)  HEX-NET CB: 0.4613.4
Data version: 20220225 DS336.1
www.Ross-Tech.com




VIN: 3VWSR69M34M106546   License Plate:




Chassis Type: 9M (1J - VW Golf/Bora IV (1998 > 2006))
Scan: 01 02 03 08 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57 75
          76
 
VIN: 3VWSR69M34M106546   Mileage: 300270km-186579miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-016-BEW.lbl
   Part No SW: 038 997 016 L    HW: 028 101 114 6
   Component: R4 1,9L EDC G000SG  3791 
   Revision: 12345678    Serial number: VWZ7Z0D9018356
   Coding: 0150031
   Shop #: WSC 01838 256 00064
   VCID: 271EFEB6972F78B7A3-5184
   VINID: 0E69E388625D0C474100614418462124DC


No fault code found.
Readiness: 0 0 1 1 1


-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1C0-907-37x-ESP-A.lbl
   Part No: 1C0 907 379 P
   Component: ESP ALLRAD MK60     0101 
   Coding: 0023049
   Shop #: WSC 31414 000 00000
   VCID: 373E2EF6478FE83733-5184


2 Faults Found:
01044 - Control Module Incorrectly Coded
            000 - -
01324 - Control Module for All Wheel Drive (J492)
            004 - No Signal/Communication


-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3Bx-907-044.lbl
   Part No: 3B1 907 044 C
   Component: CLIMATRONIC     C 2.0.0 
   Coding: 11200
   Shop #: WSC 31414 
   VCID: 210AE0AEA90B8687ED-51A8


No fault code found.


-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 F
   Component: 04 AIRBAG VW61 0202 0003 
   Coding: 12340
   Shop #: WSC 00066 
   VCID: 271EFEB6C72F78B7A3-513C


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1J0-920-xx5-17.lbl
   Part No: 1J5 920 946 C
   Component: KOMBI+WEGFAHRSP VDO V20 
   Coding: 15232
   Shop #: WSC 00050 
   VCID: 312A10EEF9EB36077D-513C


   Subsystem 1 - Part No: Clusters
   Component: By Litke     VWZ7Z0D9018356 
   Clusters By Litke     VWZ7Z0D9018356


No fault code found.


-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.clb
   Part No: 6N0 909 901
   Component: Gateway K<->CAN    0001 
   Coding: 00006
   Shop #: WSC 01266 
   VCID: 70ACD5EA32617F0F32-513C


No fault code found.


-------------------------------------------------------------------------------
Address 22: AWD        Labels: 02D-900-554.lbl
   Part No: 02D 900 554 C
   Component: HALDEX LSC  ECC     0009 
   VCID: 200CE5AAA2018F8FE2-4B3C


2 Faults Found:
01316 - ABS Control Module
            49-10 - No Communications - Intermittent
01314 - Engine Control Module
            49-10 - No Communications - Intermittent


-------------------------------------------------------------------------------
Address 29: Left Light        Labels: 7M3-907-391-29.lbl
   Part No: 7M3 907 391
   Component: EVG GDL + AutoLWR   0003 
   Coding: 00003
   Shop #: WSC 00000 
   VCID: 74A4D9FA4679432FD6-4B9A


2 Faults Found:
00496 - Sensor for Vehicle Leveling; Front
            07-00 - Signal too Low
00497 - Sensor for Vehicle Leveling; Rear
            07-00 - Signal too Low


-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr        Labels: 3B1-959-760.lbl
   Part No: 3B1 959 760 E
   Component: Sitzverstellung     0301 
   Shop #: WSC 00000 000 00000
   VCID: 2F2E1696BFDF20F76B-513C


2 Faults Found:
01008 - Note; Emergency OFF Switch is Active!
            000 - -
01000 - Motor for Rear Height Adjustment of Driver's Seat (V30)
            000 - -


-------------------------------------------------------------------------------
Address 39: Right Light        Labels: 7M3-907-391-39.lbl
   Part No: 7M3 907 391
   Component: EVG GDL + AutoLWR   0003 
   Coding: 00003
   Shop #: WSC 00000 
   VCID: 74A4D9FA4679432FD6-4BBA


No fault code found.


-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1C0-959-799.lbl
   Part No: 1C0 959 799 C
   Component: 1H Komfortgerát HLO 0003 
   Coding: 00259
   Shop #: WSC 00222 
   VCID: 373E2EF6178FE83733-4B1E


   Subsystem 1 - Part No: 1C0959801B
   Component: 17 Tõrsteuer.FS KLO 0202 


   Subsystem 2 - Part No: 1C0959802C
   Component: 17 Tõrsteuer.BF KLO 0202 


   Subsystem 3 - Part No: 1C0959811A
   Component: 1H Tõrsteuer.HL KLO 0202 


   Subsystem 4 - Part No: 1C0959812A
   Component: 1H Tõrsteuer.HR KLO 0202 


No fault code found.


-------------------------------------------------------------------------------
Address 76: Park Assist        Labels: 1J0-919-283.lbl
   Part No: 1J0 919 283 A
   Component: Einparkhilfe        0001 
   Coding: 00113
   Shop #: WSC 01266 
   VCID: 2C14019ADEC95BEF4E-513C


No fault code found.


End----(Elapsed Time: 04:11, VBatt start/end: 11.8V/11.6V. VIgn 11.4V)-----
 
   #14  

manicslothpdx

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I am stumped since the ABS module accepts the coding, but still throws the same errors after clearing them.
 
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   #15  

Jetta 97

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I think best solution get Manual Controller for Haldex and Code it to 2wd.They have very good once that you can switch form 0 to 100% of Haldex .
I think your ECU is giving you problems. That is Original ECU form TDI as I can see it .
 
   #16  

manicslothpdx

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That's a valid idea and it may come to that but I'm not ready to give up yet.

What would an alternate idea be if it was the ECU, a different ECU from a European TDI 4Motion car?

I haven't read from anyone who has done a 4Motion swap like this that they had to swap the ECU, but each swap is a different scenario.
 
   #17  

manicslothpdx

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I don't know if it matters, but one thing I should re-mention is that if we temporarily re-install my original front-wheel-drive ABS module, we can communicate with the Haldex in VCDS and run the diagnostics. It still won't activate when that ABS module is installed, but it will pass all the tests. So, some communication is capable of happening.

Having ESP seems to complicate this retrofit, too.

However, as far as I know, I have all the matching components: the MK60/4Motion ABS module, the 4Motion 3-sensor G419 sensor and the 4Motion-specific rear ABS sensors.

Could there be a missing byte that needs to be flipped in my ECU? Aren't there minimal hardware differences in the ECU's and the main differences are how they're flashed? This is an area I don't know very well, to be honest.
 
   #18  

manicslothpdx

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Graeme mentioned re-coding the CAN Gateway. Is there any visual feedback when clicking the "Do It!" button? I don't know if this is a valid test, but if we change the number, it reverts to the original number after a few moments when the screen refreshes. So, I don't know if it's having the desired effect re the new sensor modules.

When we open VCDS, the CAN Gateway code is 00006.
 
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   #19  

Uwe

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re-coding the CAN Gateway. Is there any visual feedback when clicking the "Do It!" button? I don't know if this is a valid test, but if we change the number, it reverts to the original number after a few moments when the screen refreshes. So, I don't know if it's having the desired effect re the new sensor modules.
On this (very crude, old-school) gateway, recoding it with the same value that's already there (typically always 00006), then exiting the module gracefully, shutting off the ignition for 30 seconds, and turning it back on causes the gateway to rebuild its internal installation list based on the modules that are actually communicating with it.

-Uwe-
 
   #20  

manicslothpdx

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Ah, ok. We may not have been cycling the ignition (I am coordinating with a shop remotely.)

Is this correct?

1. Clear all codes
2. Re-code CAN Gateway with 00006 and exit VCDS
3. Shut off ignition for 30 seconds
4. Run VCDS scan

Is there any step I am missing?

If it doesn't work, I will post a VCDS log in a followup post.
 
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