6R32 - Mk5 Diesel Polo to VR6 Petrol Fun & Games

[nugentp]

Another scan after the ABS basic settings completed and things looking much better here.

I found that ABS coding of either vale
230248E3437100B4C42A12E5C2D300811300 or
230248E3437100B4C42A12E5C2D300821300 was accepted, but...

I am struggling to get any sense of MPI or GTI petrol codings accepted in Bytes 04/12 and Bytes 06/14. I am expecting the ABS to get mighty confused by the torque levels coming from the BHE motor and that judicious use of the TCS/ESP cancel button is going to be needed to prevent all sorts of annoying interventions.

Monday,13,April,2026,17:33:36:30756
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86(Parallels)
VCDS Version 26.3.0.0  HEX-NET CB: 0.4701.4
Data version: 20260320 DS375.1
www.Ross-Tech.com


VIN: WVWZZZ6RZAU042532   License Plate:


Chassis Type: 6R-VW25 (6N0)
Scan: 01 03 04 08 09 15 17 19 25 44

VIN: WVWZZZ6RZAU042532   Mileage: 204600km-127132miles

01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 022-906-032-BDB.lbl
   Part No SW: 022 906 032 FA    HW: 021 203
   Component: MOTRONIC ME7.1.1G   5903 
   Coding: 0000032
   Shop #: WSC 87119 806 641192
   VCID: 4FEE7790DFA508E70A-5185
   VINID: 9E69EAAAA1A2A91940102143082880D905

No fault code found.
Readiness: 0110 1101

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 6R0-907-37x-ESP82.clb
   Part No SW: 6R0 907 379 BE    HW: 6R0 907 379 AF
   Component: ESP8.2i front H05 0001 
   Revision: --------   
   Coding: 230248E3437100B4C42A12E5C2D300811300
   Shop #: WSC 00788 648 00255
   VCID: 02488EA49977358FD5-8057

No fault code found.

-------------------------------------------------------------------------------
Address 04: Steering Angle (G085)       Labels:* 6R0-959-654.clb
   Part No SW: 6R0 959 654     HW: 6R0 959 654
   Component: LENKW.SENSOR  H06 0060 
   Serial number: 090465LJ5000ZR
   Coding: 01
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_LWSKLOVW25X 005001
   ROD: EV_LWSKLOVW25X.rod
   VCID: 7EB0FA54E18F516FB1-802B

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J301)       Labels: 6R0-820-045-9AB.clb
   Part No SW: 6R0 820 045 N    HW: 6R0 820 045 N
   Component: Man AC        H02 0202 
   Revision: 0003SH02   
   VCID: 393A2948B021B657C4-806D

1 Fault Found:
00819 - High Pressure Sensor (G65)
            009 - Open or Short to Ground
             Freeze Frame:
                    Fault Status: 01101001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 249
                    Mileage: 204605 km
                    Time Indication: 0
                    Date: 2020.09.03.
                    Time: 07:03:30

             Freeze Frame:
                    Temperature: 11.0°C
                    Time: 380.80 s
                    Time: 0.00 s
                    Voltage: 12.00 V
                    Absolute Pres.: 0.0 bar
                    Time: 0.00 s


-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 6R0-937-08x-09.clb
   Part No SW: 6R0 937 087 K    HW: 6R0 937 087
   Component: BCM PQ25 H+4  H46 0254 
   Revision: BF046001    Serial number: 0434 266121636
   Coding: 25B029B808A1060001280EC02DAB0ED8B08041FF60060000200000000000
   Shop #: WSC 12469 483 00190
   VCID: 45C255B8CCD9C2B7B0-8011

   Subsystem 1 - Part No: 1K0 955 559 AH  Labels: 1K0-955-559-AG.CLB
   Component: RLS 210912 05  54  0403
   Coding: 03302D

   Subsystem 2 - Part No SW: 6R0 959 802 AB    HW: 6R0 959 802 AB  Labels: 6R0-959-802.CLB
   Component: J386__TSG_FT  008 1621
   Serial number: KU0KU020091200018422
   Coding: 18BC30

   Subsystem 3 - Part No SW: 6R0 959 801 AD    HW: 6R0 959 801 AD  Labels: 6R0-959-801.CLB
   Component: J387__TSG_BT  008 1621
   Serial number: KU0KU017091200010077
   Coding: 18BC30

   Subsystem 4 - Part No SW: 6C0 959 442 C    HW: 6C0 959 442 C
   Component: E221__MFL-DC1  H04 0103
   Serial number: 29160000565620056125
   Coding: B0FFFF

1 Fault Found:
01758 - Bulbs for Brake Lamps
            011 - Open Circuit
             Freeze Frame:
                    Fault Status: 01101011
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 249
                    Mileage: 204605 km
                    Time Indication: 0
                    Date: 2020.09.03.
                    Time: 17:12:34


-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 6R0 959 655 K    HW: 6R0 959 655 K
   Component: VW10Airbag01X H10 0020 
   Revision: --------    Serial number: 003GX01EFA8E Dataset Number: v00307236R0 0001
   Coding: 003158
   Shop #: WSC 01383 785 00200
   ASAM Dataset: EV_AirbaVW10BPAVW250 A01001
   ROD: EV_AirbaVW10BPAVW250.rod
   VCID: 4AD86684EDC72DCF5D-801F

   Crash sensor for side airbag: driver side:
   Serial number: 3575HRB40511KADSGHBT

   Crash sensor for side airbag: passenger side:
   Serial number: 3585HRB404T1KADSF0UF

   Crash sensor for side airbag: driver side rear:
   Serial number: 3515RRB405H1GLOM6HSP

   Crash sensor for side airbag: passenger side rear:
   Serial number: 3525RRB401C4UHC45H7L

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 6R0 920 960 D    HW: 6R0 920 960 D
   Component: KOMBI         H03 0207 
   Serial number: 00000000000000
   Coding: 440E00
   Shop #: WSC 31414 790 50316
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04052
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW23.rod
   VCID: 36202274893F592F29-8063

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 6N0-909-901-6R.clb
   Part No SW: 6N0 909 901     HW: 6R0 937 087
   Component: GW-K-CAN TP20 H46 0254 
   Revision: BF046001   
   Coding: 002100
   Shop #: WSC 12469 483 00190
   VCID: 70ACD46CA3DB371F33-8025

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer
Cannot be reached

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 6Q0-423-156.clb
   Part No: 6R0 423 156 C
   Component: LenkhilfeTRW        V278 
   Coding: 11230
   Shop #: WSC 00788 
   VCID: 302C146CF75B771F73-8065

No fault code found.

End----(Elapsed Time: 01:19, VBatt start/end: 11.9V/11.9V. VIgn 11.9V)-----
------------------------------2 Faults Found-------------------------------

 

[Uwe]

Q1 - Does the ABS cross check the VIN with ECU, ICM, BCM or some combination ?

I believe this ABS does; but I'm not sure exactly with what in that car. It's usually not the ECU, but the cluster/immo when the immo is in the cluster, but again, I'm not sure the immo is in the cluster in this car...?
(We don't get Polos on this side of the pond)

-Uwe-

 

[nugentp]

It's deffo the cluster VIN which is cross-checked for ABS coding as that method was successful. For your reference IMMO4 functionality also exists within the 6R Polo cluster.

 

[nugentp]

I should really share some pics of the engine mounts and other 'fun' parts of the project, but first of all I thought I would share the wiring information for successful integration of BHE engine into the 6R platform. There is less than 20 connections needed to get the engine up and running and only a handful more for instrumentation etc. Hardest part is removing the dashboard in order to access the entry point to pull in some extra wires to/from the engine bay.

You will see that I repurposed a handful of wires from the auxiliary heating circuitry on the diesel loom to allow a future possibility of integrating cruise control (CCS). Along the way I deleted the two relays in the cabin and fuses associated with the auxiliary heat.

I also added a bunch of cables from the cabin out towards the left wing (near T14i) for future options such as an oil pressure sensor... I really don't want to be taking that dashboard out again anytime soon.

 

[Dukedesmo]

I have a particular set of skills.

I am currently rebuilding my old Land Rover and, in the process have swapped the 2.5 diesel with a 4L V8 petrol, certain skills are involved but as it's all old-school, no electronics (other than the ECU) they're not quite so particular.

Good luck...

 

[nugentp]

For the record - here is latest scan with the ABS coding to match the correct VIN which I programmed into the ICM (using VAGT software). The two fault codes annoy me, so I will look to get around those - I do like a nice clean AutoScan result. I already tried to code the BCM to ignore brake light faults for its aftermarket LED lamps but no success yet. I will have to build a simple circuit that fakes a healthy G65 signal into the HVAC to make that one go away... working on the basis of 5V signal @ 50Hz and 50% duty cycle should be adequate fakery. Some more pics will be added as time allows.

Saturday,18,April,2026,13:49:01:30756
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 26.3.0.0 (x64)  HEX-NET CB: 0.4701.4
Data version: 20260320 DS375.1
www.Ross-Tech.com


VIN: WVWZZZ6RZDY107403   License Plate:


Chassis Type: 6R-VW25 (6N0)
Scan: 01 03 04 08 09 15 17 19 25 44

VIN: WVWZZZ6RZDY107403   Mileage: 204600km-127132miles

01-Engine -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 022-906-032-BDB.lbl
   Part No SW: 022 906 032 FA    HW: 021 203
   Component: MOTRONIC ME7.1.1G   5903 
   Coding: 0000032
   Shop #: WSC 87119 806 641192
   VCID: 4FEE7790DFA508E70A-5184
   VINID: 9E69EAAAA1A2A94A410071000C5DCD2F93

No fault code found.
Readiness: 0110 1101

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 6R0-907-37x-ESP82.clb
   Part No SW: 6R0 907 379 BE    HW: 6R0 907 379 AF
   Component: ESP8.2i front H05 0001 
   Revision: --------   
   Coding: 230248E3436D00B9C42912E2C2D400821300
   Shop #: WSC 00788 648 00255
   VCID: 02488EA49977358FD5-8056

No fault code found.

-------------------------------------------------------------------------------
Address 04: Steering Angle (G085)       Labels:* 6R0-959-654.clb
   Part No SW: 6R0 959 654     HW: 6R0 959 654
   Component: LENKW.SENSOR  H06 0060 
   Serial number: 090465LJ5000ZR
   Coding: 01
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_LWSKLOVW25X 005001
   ROD: EV_LWSKLOVW25X.rod
   VCID: 7EB0FA54E18F516FB1-802A

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J301)       Labels: 6R0-820-045-9AB.clb
   Part No SW: 6R0 820 045 N    HW: 6R0 820 045 N
   Component: Man AC        H02 0202 
   Revision: 0003SH02   
   VCID: 393A2948B021B657C4-806C

1 Fault Found:
00819 - High Pressure Sensor (G65)
            009 - Open or Short to Ground
             Freeze Frame:
                    Fault Status: 01101001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 249
                    Mileage: 204605 km
                    Time Indication: 0
                    Date: 2020.09.08.
                    Time: 07:03:30

             Freeze Frame:
                    Temperature: 11.0°C
                    Time: 380.80 s
                    Time: 0.00 s
                    Voltage: 12.00 V
                    Absolute Pres.: 0.0 bar
                    Time: 0.00 s


-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 6R0-937-08x-09.clb
   Part No SW: 6R0 937 087 K    HW: 6R0 937 087
   Component: BCM PQ25 H+4  H46 0254 
   Revision: BF046001    Serial number: 0434 266121636
   Coding: 25B029B808A1060001280EC02DAB0ED8B08041FF60060000200000000000
   Shop #: WSC 12469 483 00190
   VCID: 45C255B8CCD9C2B7B0-8010

   Subsystem 1 - Part No: 1K0 955 559 AH  Labels: 1K0-955-559-AG.CLB
   Component: RLS 210912 05  54  0403
   Coding: 03302D

   Subsystem 2 - Part No SW: 6R0 959 802 AB    HW: 6R0 959 802 AB  Labels: 6R0-959-802.CLB
   Component: J386__TSG_FT  008 1621
   Serial number: KU0KU020091200018422
   Coding: 18BC30

   Subsystem 3 - Part No SW: 6R0 959 801 AD    HW: 6R0 959 801 AD  Labels: 6R0-959-801.CLB
   Component: J387__TSG_BT  008 1621
   Serial number: KU0KU017091200010077
   Coding: 18BC30

   Subsystem 4 - Part No SW: 6C0 959 442 C    HW: 6C0 959 442 C
   Component: E221__MFL-DC1  H04 0103
   Serial number: 29160000565620056125
   Coding: B0FFFF

1 Fault Found:
01758 - Bulbs for Brake Lamps
            011 - Open Circuit
             Freeze Frame:
                    Fault Status: 01101011
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 249
                    Mileage: 204605 km
                    Time Indication: 0
                    Date: 2020.09.08.
                    Time: 17:12:34


-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 6R0 959 655 K    HW: 6R0 959 655 K
   Component: VW10Airbag01X H10 0020 
   Revision: --------    Serial number: 003GX01EFA8E Dataset Number: v00307236R0 0001
   Coding: 003158
   Shop #: WSC 01383 785 00200
   ASAM Dataset: EV_AirbaVW10BPAVW250 A01001
   ROD: EV_AirbaVW10BPAVW250.rod
   VCID: 4AD86684EDC72DCF5D-801E

   Crash sensor for side airbag: driver side:
   Serial number: 3575HRB40511KADSGHBT

   Crash sensor for side airbag: passenger side:
   Serial number: 3585HRB404T1KADSF0UF

   Crash sensor for side airbag: driver side rear:
   Serial number: 3515RRB405H1GLOM6HSP

   Crash sensor for side airbag: passenger side rear:
   Serial number: 3525RRB401C4UHC45H7L

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 6R0 920 960 D    HW: 6R0 920 960 D
   Component: KOMBI         H03 0207 
   Serial number: 00000000000000
   Coding: 440E00
   Shop #: WSC 31414 790 50316
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04052
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW23.rod
   VCID: 36202274893F592F29-8062

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 6N0-909-901-6R.clb
   Part No SW: 6N0 909 901     HW: 6R0 937 087
   Component: GW-K-CAN TP20 H46 0254 
   Revision: BF046001   
   Coding: 002100
   Shop #: WSC 12469 483 00190
   VCID: 70ACD46CA3DB371F33-8024

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer
Cannot be reached

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 6Q0-423-156.clb
   Part No: 6R0 423 156 C
   Component: LenkhilfeTRW        V278 
   Coding: 11230
   Shop #: WSC 00788 
   VCID: 302C146CF75B771F73-8064

No fault code found.

End----(Elapsed Time: 01:25, VBatt start/end: 12.0V/11.9V. VIgn 11.8V)-----
------------------------------2 Faults Found-------------------------------

 

[nugentp]

Some pics of the 6R32 engine mount challenge... to say its a neat fit is an understatement :-)



Not much space between the crankshaft pulley and the chassis leg...


Not much space on the gearbox side either...


We used an existing notch in the right chassis leg for the driveshaft (as this Polo runs on air springs so its can sit super low to the floor for the car show vibe) to size up where the powertrain needs to sit without silly angles on the CV joints.



With the help of our friendly neighbourhood fabrication man and some 3" hockey pucks we made three custom engine mounts and some judicious cuts in the subframe to provide clearance to the gearbox. I think these older 02M differentials like on our DRP box must be bigger than the 02M derivatives used in the 6R/8X version of the 6MT transmission.


Block side mount here was made from scratch with 5mm steel and an offcut from some hefty pipe that was 3" diameter to marry up the rubber puck...





The gearbox side was trickier due to way it folds over the left chassis leg, so we modified the OE mount in a funky way so it could pickup the gearbox mount points with some hefty stand-off sections so the thing is held at the correct angle.

 

[nugentp]

Here are the left & right mounts painted up...



We started making some cuts in the subframe to give us clearance...
Ended up with a rather large section removed, then welded up before painting...


That in itself did not create anything like enough clearance for the rear pendulum 'dog bone' mount so we had to get creative and fabricate a kind of 'dogs dinner' mount on the subframe with another hockey puck serving up duty as the insulation layer between all this rigid heavy metal.

 

[nugentp]

With the time crunch at the end for our show deadline, there actually aren't any decent photos of the engine side of the dog's dinner mount at the rear, but if you can conceive of a dog-leg shaped square section with a flange that mounts to these 4 x rear holes in the block (normally reserved for an engine stand) which provides the other side of the 3" cup/bowl for the hockey puck then you are sort of there. I will try to get better pics if anyone needs them.

 

[nugentp]

The exhaust was the other tricky part where we had to get professional assistance from a local exhaust specialist - working with the driveshafts and engine mounts in situ - squeezing 2 x 55mm downpipes into the unmodified 6R tunnel where they were merged into a 70mm system with two silencers. We need to go back for a CAT fitment and maybe an X-pipe upstream of that if there is room. This was done from scratch on the day before the car needed to be at an event so like no pressure lads :-)

 

[nugentp]

Swapping the fuel tank from diesel to petrol was kind of tedious but not too bad once you accept the exhaust and rear beam needs to be removed first of all, so we refurbished the beam with POR15 treatments, power flex bushes and new flexi lines for the brakes. We sourced a 6R polo petrol tank - knowing it had the wrong fuel pump for the R32 requirements but the pump from a 1.8GTi (or 2.0 WRC) Polo provides more than enough flow for ~300bhp. We sourced an OE quality pump from Pierburg (7.05656.08.0) and went about making supply and return lines from 8mm PA12 nylon hose as the pipes on the diesel tank are not quite the correct shape. It's quite time consuming making those little link pipes with all their twists & turns - a hot air gun, a bucket of water and patience is required. I added some protective sleeving just in case but they worked out ok.


This tool is very very useful for pushing on the nylon fittings... the 90˚ fittings are the trickier ones that require a bit more care that everything stays nicely aligned.



Amazingly, when Hans & Franz designed the 6R Polo chassis, they left accommodation on the chassis for EITHER the diesel or petrol tank to be fitted. The 6R petrol tank of that era comes with its own activated carbon canister nearby. The chassis has the necessary clip and fixing hole for that and the tank mounts up to the body the same way.


Naturally, the upper M6 fixing had to shear on removal (should have soaked it with penetrant first), but some careful drilling made good. Care was also taken with copper grease to ensure this upper fixing has good clean earth connection as there is an earth strap up there as part of the filler neck assembly.

Then it was simple enough to run 3 x fresh fuel lines (again 8mm OD PA12) from the tank up to the engine bay. Red for supply, Blue return and Green for EVAP.


It was no problem re-using the OE fuel clips either and that little channel on the right side...

 

[nugentp]

Just to cover off the fuel pump topic more completely. The OE part for the 1.8GTi Polo maps to Bosch P/N 1-987-580-041 as well as the Pierburg item. I found reliable data for the Bosch pump stating its capability to deliver 135lph at 4bar. A 250bhp VR6 engine needs a little under 100lph even with some headroom for margin so that is plenty good enough.

The other small consideration was the fuel filter. The BHE motor has fuel rail expecting flow & return connections so we needed a simple in-line fuel filter with 8mm fixing that was small enough (55mm diameter) to be located in the bracket integrated on the fuel tank. I found the fuel filter from an 8P S3 (~265bhp) fitted the bill in terms of dimensions and sourced the Bosch equivalent 0-450-905-316 (aka F5316) for that.



When we flow tested the fuel system with the BHE fuel rail (4bar) and the fuel filter with the Pierburg pump, we measured 811g of fuel in 30 seconds... that's 1.622kg per minute ==> 97.32kg/hr ==> 130lph with UK E5 fuel density of 0.75kg/liter. That was at 12.5V on the pump.

 

[nugentp]

As we had the engine up and running on a bench test rig to verify it was basically in good health, knowing that we wouldn't have room for HVAC and that the Polo has electric powered steering, we had the opportunity to remove two sources of parasitic loss on the engine. Selecting a 6PK1100 poly v-belt allowed is to drive just the water pump and the alternator... we later dropped down to a 6PK1090 for better tension and may yet see if a slightly shorter one is going to be better again.

 

[nugentp]

More pics to come soon for posterity - not been online the past week. We did get the 6R32 for its first proper test tonight and it sure sounds delicious - seems wrong for an ickle Polo to sound like that.

I have a bit more ECU tickling to do before the rear O2 sensors are fully ignored but that's an easy enough to sort.

One niggle I was expecting was intermittent "rough road" faults on the ECU relating to the ABS but that's most definitely because the 8N generation of ECU expects different message set or scaling than what the 6R generation ABS is broadcasting. When you manually disable ESP/TCS then that fault goes away so a bit of advanced ECU tickling will be needed to sort that out. I have an ME7 specialist lined up to help on that front.

Something I did not expect is that the scaling from the G266 sensor on the BHE engine is not what the 6R petrol cluster expects as we see -60C permanently displayed in measuring blocks. I may have to see if a G266 sensor from 6R era will mechanically work in the VR6 engine.

Anyone know if the G266 sensor scaling was changed across the years or platforms or what is a good reference to research this ?

 

[nugentp]

Answering part of my own question - seems like SSP 233 was the first mention of the oil level / temp sensor circa 1999 and so I would expect the BHE motors sensor to behave in that way. Wondering now if the platform or power class coding in the instrument cluster has any bearing on how the oil sensor signal is interpreted.

I did not change the petrol cluster coding bytes so they may be in conflict with whatever the BCM is configured with (from factory as diesel) and I wonder if that is relevant.

 

[nugentp]

So now the plot thickens - I fished out the VIN from the 6R cluster that came from some random petrol Polo at a nice low price - turned out to be a 1.2 MPI with the CGPB engine and that one apparently doesn't use an oil level sensor - unlike the 1.2 or 1.6 diesel engines amongst others (ironic).

I was looking at KOMBI-3 signals on the CAN Bus from a capture I had on the run-rig when the TT instrument cluster module (ICM) was in use. You can see oil and water temps being sent by the ICM on message id 0x420. When I sniff that message with the 6R32 up and running, its clear to see -60˚C being signalled (in terms of ME7 scaling anyway) as oil temp.

Now I wonder if I can code the 6R petrol cluster differently so it does broadcast the oil temp info onto CAN Bus as the ECU is expecting it (and coolant temperature which is weird as the ECU has a direct sensor input for that which I expect it uses as the primary source of info) - or maybe I need 6R cluster from a different 6R petrol engine such as 1.4GTi to get that functionality working.

Any insight from the 6R experts would be welcome - I don't relish having to burn different code into the ICM.

 

[nugentp]

I have a horrible feeling we need to source 6R GTi clocks (CAVE engine) for this to all work correctly - not an impossible task, but good condition ones are expensive and then I have to go thru the EEPROM hacking and VAGT pokery to unlock it, extract the PIN all over again. The CAVE engine uses exactly same oil sensor as the VR6 BHE motor (1J0 907 660 C) and the GTi clocks have a radical feature by way of a coolant temperature needle which lesser Polo models did not get.

Am I right in saying that clocks from a 6C generation of Polo will not be compatible with other 6R components on the car ?

 

[Dukedesmo]

Can't help with any of your questions but, having previously owned an Audi A3, 3.2 and, at the same time my Son had a 1.2 Polo, I can only imagine what the 'lovechild' of the two might drive like.

Project looks to be coming along nicely, well done!

 

[nugentp]

So here is the smoking gun - I have a partially built DBC file in SavvyCAN and captured this with my PCAN-USB-Pro bus sniffer. I am using scaling information found in an ME7 'FR' document for an engine of similar vintage and this pretty much confirms the 1.2 MPI Polo cluster (6R0 920 960 D) does not process coolant temp or oil temp/level info. Some bits in the first byte (0x84) are signalling error conditions in respect to oil temp and coolant temp, so I guess that explains why the ECU is presumably ignoring the values.

Other values for things like steering angle, VSS, RPM are working perfectly as per the German FR doc.

 

[nugentp]

There are SO many photos... I can share the highlights here and if anyone needs more detail for their own conversion I will be happy to help if I can.

After a suitable amount of time familiarising myself with the VR6 engine schematics and the 6R Polo wiring I was able to hatch a plan. The first annoyance is that the 6R Polo doesn't use a modular wiring scheme like the PQ34 family cars (8L/8N etc) so all the nice clean connectorised plugs on the vehicle side of the engine loom which would connect in the plenum box of a Mk1 TT need to be carefully documented (as shown above) so they can be spliced into similarly well documented wires on the 6R loom.

I wanted to save space and reduce complexity by using the fuel pump relay (FPRy) and engine control relay (ECRy) from the Polo wiring and I figured a way to repurpose the engine fuses from the Polo cabin so I didn't have to go crazy with the wire snippers inside the car - just the engine bay.

Below is the BHE engine loom - vehicle side as it came from the TT application - you can see the ugly wart box which housed the ECRy and Satans Air Injection (SAI) pump relay... I think by the time this pic was taken I had already stripped out he SAI cabling.



A bit of careful editing of the ECRy related wires on the loom and it was ready to offer up to the Polo...