MK5 Golf 1K Problem calabrating steering. code 02546 and 00778

   #1  

Pinpointdiag

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Hi all. Can i ask for advice with this one please, i know it can cause problems and i have read lots of posts here. And I have have read and followed the instructions on the wiki. This car has ate mk60 abs esp so the steering angle sensor is under the steering wheel. and requires basic setting in the abs.

I have tried dozens of times now to reset this. with short drives, long drives, longer periods of key off and on cycles.etc. I have carried out this procedure on many vag vehicles with vcds over the years and while some have taken a few attempts. and some I have had to find faults before it would work. This one is getting the better of me at the moment.

The vehicle came to me a few weeeks ago. The customer had had a flat battery and got another garage to get it started. They then found the steering required resetting. Which they attemted to do with a snap on scan tool. When that failed to work they jumped to the conclusion that it must have a faulty steering angle sensor. Probably due to the fault code and live data showing zero degrees at all times. They also thought the sensor was in the steering rack.

Then they found a new rack was very expensive. but found they could get a reconditioned rack through a local motor factor. The customer agreed and the recon rack was fitted but they still could not set the steering angle sensor. At this point the gave up and told the customer they could do no more.

Thats when i got involved the story i got was "I have had a new steering rack fitted can you calabrate the angle sensor". So when it arrived I found some fault codes, there was a code for one of the speed sensors incoherent, a code for the yaw rate sensor and a code for a communication fault between the abs and the steering assist modules. graphing the speed sensors proved there was a fault with the left hand rear and i knew that would stop it calabraiting. So I checked this first it had a bad reluctor and the rusty magnets had been hitting the sensor. so new hub and sensor now all sensor outputs look good.

The customer tells me she had seen the traction control light coming on sometimes before this all started It still would not calabrate and the yaw sensor code had not returned after a long test drive so I then looked at the communication fault code. it turned out the 44 steering assist, ie the recon rack wich i allready thought had not been required was set up for a mk70 abs and when i changed it to mk60 the fault changed from communicatio error to no communication.

By luck the other garage still had the old rack so i got a hold of it and plugged it in and the comms code cleared. I suspect that the replacement rack was the wrong part number or incompatable some how.

So i recommended they get the previous garage to refit the old rack. That was three weeks ago. I had told them to come straight back if they still had problems setting it. I thought it must have been ok. but now its back.. still not working!

There are now no other codes but the two for steering limit stops not set and steering angle sensor fault 02546 and 00778. The wheel speeds look consistant, esp sensors look ok in live data If in abs i enter access code and go to basic settings choose steering angle and hit go the it says ok. if i set the wheel to any other position other than straight ahead it says not ok. so i think thats ok its not completing the next end stop reset bit.

However i noticed if its 360 deg out ether way it will still say ok when you try resetting. So i thought maybe they had let the column spin when the rack was off. so i removed the steering wheel to check the clock spring. I found the sensor is the led and mask type which has the mask as part of the clock spring and the sensor is wired separately.

How does it know when the wheel has past the first 360 deg, is it calculated?

Any way i tried moving the clock spring one turn to the the left. and then one turn to the right. still did not work. The clock spring is not like most where it winds up one way and unwinds the other way. so I could not prove it was central.

Also i remember there was a fault code for the yaw sensor when i first looked at the car.weeks ago.
and i wonder if it has an intermittnt fault with that causing the reset problem. In live data the rotation rate is always about 1.1deg/sec

What am i missing?

Sorry about the long post. and any bad spelling.

Hope some one can help
Thanks for reading
Alan from Pinpoint Automotive
 
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   #2  

Pinpointdiag

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Here is the most recent auto scan of the Golf
Cheers Alan
Code:
Tuesday,24,May,2016,19:37:31:05279
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x86
VCDS Version: 15.7.4.1
Data version: 20160216
www.Ross-Tech.com


VIN: WVWZZZ1KZ6B003850   License Plate: BN55 SGX
Mileage: 179960km-111821mi   Repair Order: 1



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


Chassis Type: 1K (1K0)
Scan: 01 03 08 09 15 16 17 19 25 42 44 46 52 56 7D

VIN: WVWZZZ1KZ6B003850   Mileage: 179960km-111821miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
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: Malfunction 0010
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: Malfunction 0010
7D-Aux. Heat -- Status: Malfunction 0010
 
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 03G-906-016-BKC.lbl
   Part No SW: 03G 906 016 CB    HW: 028 101 190 0
   Component: R4 1,9L EDC 0000SG  6176  
   Revision: 12345678    Serial number: VWZ7Z0E2160871
   Coding: 0000071
   Shop #: WSC 00046 412 08192
   VCID: 65C5E970AC755916ED-8030

3 Faults Found:
17055 - Cylinder 1 Glow Plug Circuit (Q10) 
            P0671 - 000 - Electrical Fault
             Freeze Frame:
                    RPM: 903 /min
                    Torque: 38.0 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.29 V
                    Bin. Bits: 11000111
                    Temperature: 9.9°C
                    Bin. Bits: 10110000

17057 - Cylinder 3 Glow Plug Circuit (Q12) 
            P0673 - 000 - Electrical Fault
             Freeze Frame:
                    RPM: 903 /min
                    Torque: 38.0 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.29 V
                    Bin. Bits: 11000111
                    Temperature: 9.9°C
                    Bin. Bits: 10110000

17058 - Cylinder 4 Glow Plug Circuit (Q13) 
            P0674 - 000 - Electrical Fault
             Freeze Frame:
                    RPM: 903 /min
                    Torque: 38.0 Nm
                    Speed: 0.0 km/h
                    Load: 0.0 %
                    Voltage: 14.29 V
                    Bin. Bits: 11000111
                    Temperature: 9.9°C
                    Bin. Bits: 10110000

Readiness: 0 0 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK60-F.lbl
   Part No SW: 1K0 907 379 Q    HW: 1K0 907 379 Q
   Component: ESP FRONT MK60      0102  
   Revision: 00T12001    
   Coding: 0021121
   Shop #: WSC 00046 551 00000
   VCID: 408B18E413975C3E3E-8014

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-820-047.lbl
   Part No: 1K0 820 047 DF
   Component: Climatic PQ35   090 0505  
   Shop #: WSC 00000 000 00000
   VCID: 6BD19F484A916F66BB-803E

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 3C0-937-049-23-M.lbl
   Part No SW: 3C0 937 049 D    HW: 3C0 937 049 D
   Component: Bordnetz-SG     H37 1002  
   Revision: 00H37000    Serial number: 00000001763680
   Coding: 00890F2700041800001400001400000000087B075C
   Shop #: WSC 00046 412 761856
   VCID: 2A5F5A4C85EBB66E00-807E

   Subsystem 1 - Part No: 1K2 955 119 C  Labels: 1KX-955-119.CLB
   Component: Wischer VW350  012  0402  
   Coding: 00065493
   Shop #: WSC 00046  

1 Fault Found:
02394 - Parking Light Left Front (M1) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 18
                    Mileage: 179937 km
                    Time Indication: 0

             Freeze Frame:
                        ON
                    Voltage: 12.05 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 N    HW: 1K0 909 605 N
   Component: 08 AIRBAG VW8   015 2100  
   Revision: 03015000    Serial number: 0038ED0DRAMO  
   Coding: 0012344
   Shop #: WSC 00046 412 08192
   VCID: 3779733846591B868F-8062

   Subsystem 1 - Serial number: 6332MSME0A264C72E

   Subsystem 2 - Serial number: 6342MSME0A123541+

   Subsystem 3 - Serial number: 6351HSME07475E60A

   Subsystem 4 - Serial number: 6361HSME07501C373

1 Fault Found:
00588 - Airbag Igniter; Driver Side (N95) 
            001 - Upper Limit Exceeded - MIL ON

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 AE    HW: 1K0 953 549 AE
   Component: Lenksäulenmodul 034 0070  
   Coding: 0000002
   Shop #: WSC 00046 412 516096
   VCID: 75E5B9301CD5A9965D-8020

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No: 1K0 920 952 B
   Component: KOMBIINSTRUMENT VDD 1012  
   Coding: 0003403
   Shop #: WSC 00046 067 57207
   VCID: 295DA54080EDBD7609-807C

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 1K0-907-530-V1.clb
   Part No SW: 1K0 907 530 F    HW: 1K0 907 951 
   Component: Gateway         H10 0120  
   Revision:   H10       Serial number: 28001055098569
   Coding: 3D0F0B40070003
   Shop #: WSC 00046 412 1400832
   VCID: 2A5F5A4C85EBB66E00-807E

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No: 1K0 920 952 B
   Component: IMMO            VDD 1012  
   Shop #: WSC 00000 000 00000
   VCID: 295DA54080EDBD7609-807C

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels: 1K0-959-701-MIN2.lbl
   Part No: 1K0 959 701 K
   Component: Tuer-SG         024 2312  
   Coding: 0000692
   Shop #: WSC 00046 412 761856
   VCID: 36677E3C4153E28E94-8062

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-14x-44.clb
   Part No: 1K2 909 144 J
   Component: EPS_ZFLS Kl.5   D04 1606  
   Shop #: WSC 00000 000 00000
   VCID: 336147285221F7A6B3-8066

2 Faults Found:
02546 - Steering Limit Stop 
            005 - No or Incorrect Basic Setting / Adaptation
             Freeze Frame:
                    Mileage: 9920 km
                    Temperature: 37.0°C
                    Voltage: 14.40 V
                    Voltage: 14.20 V

00778 - Steering Angle Sensor (G85) 
            000 -  - 
             Freeze Frame:


-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 1K0-959-433-MIN.clb
   Part No: 1K0 959 433 AK
   Component:    KSG              0401  
   Coding: 00C802087F2D8405485B018010CC
   Shop #: WSC 00046 412 761856
   VCID: 79FDB50030CDCDF639-802C

   Subsystem 1 - Component:   Sounder n.mounted     

   Subsystem 2 - Component:       NGS n.mounted     

   Subsystem 3 - Component:      IRUE n.mounted     

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels: 1K0-959-702-MIN2.lbl
   Part No: 1K0 959 702 K
   Component: Tuer-SG         024 2312  
   Coding: 0000692
   Shop #: WSC 00046 412 761856
   VCID: 3779733846591B868F-8062

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
   Part No SW: 1K0 035 186 P    HW: 1K0 035 186 P
   Component: Radio FO3       013 0009  
   Revision: 00013000    Serial number: VWZ7Z2E0005443
   Coding: 0020200
   Shop #: WSC 00046 412 516096
   VCID: 336147285221F7A6B3-8066

1 Fault Found:
00003 - Control Module 
            014 - Defective

-------------------------------------------------------------------------------
Address 7D: Aux. Heat        Labels: 1K0-963-235.lbl
   Part No SW: 1K0 963 235 E    HW: 1K0 963 235 E
   Component: PTC-Element         0404  
   Revision: 00800000    Serial number:               
   Shop #: WSC 00000 000 00000
   VCID: 2D555150B405A156E5-8078

1 Fault Found:
00361 - Heater Element for Auxiliary Heater (Z35) 
            014 - Defective

End-------------------------(Elapsed Time: 01:41
)------------------------
 
   #3  

Jack@European_Parts

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STOP!

Address 44: Steering Assist Labels: 1Kx-909-14x-44.clb
Part No: 1K2 909 144 J
Component: EPS_ZFLS Kl.5 D04 1606
Shop #: WSC 00000 000 00000 <<<<<<<<<<<<<<<<<<<<<<<<< Recode/login the sensor to default 0x44 and try a recalibration after reboot!
VCID: 336147285221F7A6B3-8066




Be sure the WSC, tester # and importer ID are other than zero in VCDS!

http://forums.ross-tech.com/showthr...essional-Problem-Solver-Guide-quot-JPPSG-quot
 
   #4  

Pinpointdiag

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Hi Jack thanks for your reply.
Can I ask if you can expand a little. You are correct in my laptop the wsc importer and tester were all zero.
I have changed that. Switched off rebooted laptop
Am I supposed to change this also in address 44 as you have highlighted.
As I can't see how to do that.
Thanks alan
 
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Jack@European_Parts

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Correct.....
It should do it when you login to do a basic settings or clear an ADP if available.

When in 0x44 please make a screen shot of available function buttons.



Further I have been finding that 0x44 after an ABS module ( all versions ) is replaced, it will need an ADP with login.
The Wiki appears to state that this isn't needed or doesn't apply to MK60 series modules ........and it does.
 
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   #6  

Pinpointdiag

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Ok in address 44 . Can't log in with 40168 in security access 16 but in coding 11-11 it says log in accepted
Then in basic settings it has steering angle sensor only. which under documented basic settings only has adjustment of
Steering angle 060 which gives adjustment not possible, status 0 g85 n/a. Not surprised by that as I know the sensor is not in the rack. Then changed one of the available adaption channels. Restarted and ran auto scan again.
Still all zeros in 44 wsc etc
Alan
 
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Pinpointdiag

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Is there an easy way to post a screen shot
 
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Pinpointdiag

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Hi is this is this the screen capture you wanted

http://postimg.org/image/c03by1oxn/

vcds_screen.png
 
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Jack@European_Parts

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See where it says adaptation?

0x44-10

Click there and see if channel zero exists please. 0x44-10-000 if it does save it at same data and may say clear defaults......

If not do the login in 16

0x44-16- should be displayed in VCDS.
 
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Pinpointdiag

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Hi again, yes tried that and although 000 is not in the drop down box. If I try it anyway it says reset to factory basic.
Done that rebooted everything even tried disconnecting car battery for a while.
Rerun scan but wsc is still all zeros in 44. Checked that in 44 adaptions it's still set for mk60 abs
Then had another go at steering angle Adaptions. Still no joy.

The adaptions drop down box in 44 has 9 items but most don't appear to do anything. Inc the last one steering angle sensor with or without
Could this be relevant. Also the on/off/next button on some adaptions and basic settings just changes things to not possible
Can I ignore that as it seems to adapt when you just press go.
Thanks for helping by the way is very much appreciated
Alan
 
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Jack@European_Parts

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Go to the 0x03 ABS and see if you do the adaption there if it allows for the test and happens to broadcast on the CAN back to 0x44.
Do you only get a pull down menu in adaption in 0x44 and no ability to enter anything being UDS?
Have you checked wiring and the 0x44 controller for any damage/tampering?
 
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Pinpointdiag

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Ok will be Monday now before I can get back to this.

The rack with 0x44 had been removed and refitted by previous garage. However I
did have the wiring out so I could plug It in to the old one before it was refitted.
plugs looked ok and wiring ok back as far as I looked at the time.

I'll check wd on Monday, I can scope test the CAN. Load test feeds and earths etc.
However the car had no problem until It had a flat battery.
Of course a new fault may have been added since then.

I think I have tried both basic settings and adaptions in 0x03 but I'll try again.
As maybe not since I altered the wsc in vcds.

Could it be a faulty steering angle sensor or maybe dust on the sensors
Or a wheel alignment fault as the other garage may have swapped the track rod
From one rack to the other.

Does any one know what is being measured when turning lock to lock.
Is it taking motor currant in to account. Or is it just the 10 seconds you hold it there

Thanks Alan.
 
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   #15  

NEtech

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And you have double checked there is no problems with wheel sensor signals?
Drive around, start - stop (up to 20-30 km/h), looking at measurement values, with VCDS scope (or real scope).
 
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Pinpointdiag

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I have a Snap-on graphing scan tool that's very good and quick to check wheel speeds, any I have seen in the past
were picked up by this. However I also have a four channel pico scope. Do you think I should scope all four
and check for any drop outs before going any further? The left hand rear hub was pretty bad, the right hand
may have one little mark on a magnet. Not enough for a fault code or even to be clear on a graph.
Could it be as sensitive as that?
 
   #17  

Jack@European_Parts

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Is there a deviation when watching all four sensors simultaneously?

Please log the data.
 
   #18  

Pinpointdiag

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Hi again back on this.
There is no deviation between all four wheels when driving 5-20 mph. I also checked with scope but only two post lift so front ones driven rear ones spun by hand.
no drop outs.

Wiring in to steering assist controller looks ok. I could check feeds and earths and scope test CAN if you think it's worth a try. However is this not a function of the mk60 abs and the angle sensor under the steering wheel on this vehicle?

You can enter other adaptions in 0x44, tried 000 reset to factory. Made no difference.However I notice some adaptions are not available. For instance the last one , Steering angle sensor present or not. Can't be altered

The wsc is still at zero in 0x44 after adaptions basic settings and codeing all altered in abs and steering assist
Any thoughts.
Cheers again Alan.
 
   #20  

Pinpointdiag

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Sorry Jack it's been almost three weeks since I last asked about this car. You were helping and advised I try 0x44 10 000
Sorry if I have confused things. I know the procedure for basic setting for steering angle and limit stops on a mk60 abs
Must have tried 50 times on this car with lots of variations. Like longer key cycles and drives.
 
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