2004 VW Polo 1.9 TDi BLT glow plug relay testing help

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   #1  

andythechief

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Hi- car starting and running fine, but keep getting an EML which is a problem for the MOT test here in the UK. I have ignored this fault for a long time, but I am determined to solve it once and for all....albeit not by myself apparently.

So I have tested the following:
- glow plugs all showing continuity
- using VCDS output tests, I can verify that 0V and 12V cycling to each glow plug exists ( which I assume is what the test is supposed to do )

The part number for the J179 glow plug relay on this car is 038907281C and it is located next to the battery. It has been replaced with a genuine part from VW which was replaced between the two Autoscans below. VW struggled to find the correct part number so the one from the old unit was used to obtain the one on the car now.

The glow plugs in the car were also replaced- they are now Beru with markings on them of: Beru Germany 242, 0100 226 482 11V. I don't know if these were supplied by VW.

What I would like to do is some more testing to verify function of the glow plugs, perhaps by taking them all out and making the circuit function.

Is there a way to force the relay to turn on all the glow plugs for a more sustained period of time than in the VCDS output tests? Each time I run the VCDS output tests I have to power cycle the ECU on the car to run them again and they will only run for about a minute it seems.

Is there a way to test the J179 glow plug control module / relay?

Here in the UK the weather rarely gets cold enough to suffer from glow plugs which do not work properly, and this car has always started without issue. I just want to get rid of the EML which keeps coming back.

thanks in advance for any assistance.

Andrew




Autoscan just now:

Code:
Sunday,12,March,2017,10:55:42:61795
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 17.1.3.0 (x64)
Data version: 20170220 DS267.3
www.Ross-Tech.com


VIN: WVWZZZ9NZ5D023423   License Plate:
Mileage: 138870km-86289mi   Repair Order: 



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


Chassis Type: 9N (9N - VW Polo (2002 > 2010))
Scan: 01 02 03 08 09 15 17 19 25 37 44 45 46 56 76
 
VIN: WVWZZZ9NZ5D023423   Mileage: 138870km-86289miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-019-ASZ.lbl
   Part No: 038 906 019 NJ
   Component: 1,9l R4 EDC 0400SG  6412  
   Coding: 00002
   Shop #: WSC 31414  
   VCID: 6CD048EE1C7A942125-4B28
   WVWZZZ9NZ5D023423     VWZ7Z0D0274798

1 Fault Found:
17057 - Cylinder 3 Glow Plug Circuit (Q12) 
            P0673 - 35-10 - Electrical Fault - Intermittent
Readiness: 1 1 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 6R0-907-37x-ABS80.lbl
   Part No SW: 6Q0 907 379 AA    HW: 6Q0 907 379 AA
   Component: ABS 8.0 front   H03 0001  
   Revision: 00000000    Serial number: 00000000000000
   Coding: 0000008
   Shop #: WSC 31414 000 00000
   VCID: 7CF078AE3C1A04A1B5-5168

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 6Q0-820-045.lbl
   Part No: 6Q0 820 045 
   Component: Klimaanlage        X0840  
   VCID: 6ADC4EF6168E8A1157-5168

1 Fault Found:
01596 - Motor for Outside/Recirculated Air Flap (V154) 
            30-00 - Open or Short to Plus

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 6Qx-937-049-C.lbl
   Part No: 6Q1 937 049 D
   Component: 0000 BN-SG.         1S34  
   Coding: 09406
   Shop #: WSC 31414  
   VCID: 3C70B8AE2C9AC4A1F5-5168

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 K
   Component: 18 AIRBAG VW51 0P   0008  
   Coding: 12600
   Shop #: WSC 31414  
   VCID: 2C5088EEDCFA542165-5168

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 6Q0-920-xxx-17.lbl
   Part No: 6Q0 920 922 F
   Component: KOMBI+WEGFAHRSP VDO V19  
   Coding: 01468
   Shop #: WSC 00014  
   VCID: 3566AD8A0FB015E90A-5168
   WVWZZZ9NZ5D023423     VWZ7Z0D0274798

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: 001K GATEWAY CAN    1S34  
   Coding: 00014
   Shop #: WSC 31414  
   VCID: 70E85C9E305270C119-5168

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 6Q0-423-156.clb
   Part No: 6Q0 423 156 AB
   Component: LenkhilfeTRW        V270  
   Coding: 00140
   Shop #: WSC 31414  
   VCID: 6FEA5FE22D6C6F3900-5168

No fault code found.

-------------------------------------------------------------------------------
Address 45: Inter. Monitor        Labels: 6Q0-951-171.lbl
   Part No: 6Q0 951 171 
   Component: Innenraumueberw.    0019  
   VCID: 6FEA5FE22D6C6F3900-5168

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 6Q0-959-433.lbl
   Part No: 6Q0 959 433 E
   Component: 4U Komfortgerát     0002  
   Coding: 00066
   Shop #: WSC 31414  
   VCID: 3D76B5AA3780CDA9C2-4B28

   Subsystem 1 - Part No: 6Q1959801A
   Component: 4U Tõrsteuer.FS TFK 0004  

   Subsystem 2 - Part No: 6Q1959802A
   Component: 4U Tõrsteuer.BF TFK 0004  

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1J0-035-18x-56.lbl
   Part No: 6N0 035 186 B
   Component:  Radio BNO         0006  
   Coding: 06403
   Shop #: WSC 31414  
   VCID: 2D5685EAE7E05D2972-4B28

No fault code found.

End-------------------------(Elapsed Time: 02:55)--------------------------

Same car, few years ago:

Code:
Wednesday,06,March,2013,18:21:38:31207
VCDS Version: Release 11.11.5
Data version: 20121222



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


Chassis Type: 9N - VW Polo
Scan: 01 02 03 08 09 15 17 19 25 37 44 45 46 56 76
 
VIN: WVWZZZ9NZ5D023423   Mileage: 96740km/60111miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 038-906-019-ASZ.lbl
   Part No: 038 906 019 NJ
   Component: 1,9l R4 EDC 0400SG  6412  
   Coding: 00002
   Shop #: WSC 31414  
   VCID: 6CDC0C261CF21078ED4
   WVWZZZ9NZ5D023423     VWZ7Z0D0274798

4 Faults Found:
17068 - Glow Plug Control Module (J179) 
            P0684 - 35-00 - Implausible Signal
18263 - Powertrain Data Bus 
            P1855 - 35-00 - Software Version Monitoring
17571 - Fuel Temp Sensor (G81) 
            P1163 - 35-00 - Open or Short to Plus
17664 - Engine Coolant Temp Sensor (G62) 
            P1256 - 35-00 - Open or Short to Plus
Readiness: 1 3 0 0 0 

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 6R0-907-37x-ABS.lbl
   Part No SW: 6Q0 907 379 AA    HW: 6Q0 907 379 AA
   Component: ABS 8.0 front   H03 0001  
   Revision: 00000000    Serial number: 00000000000000
   Coding: 0000008
   Shop #: WSC 31414 000 00000
   VCID: 7CFC3C663C9280F87D4

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 6Q0-820-045.lbl
   Part No: 6Q0 820 045 
   Component: Klimaanlage        X0840  
   VCID: EAD08A3E96068E481F8

2 Faults Found:
65535 - Internal Control Module Memory Error 
            00-00 -  - 
01596 - Motor for Outside/Recirculated Air Flap (V154) 
            30-10 - Open or Short to Plus - Intermittent

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels: 6Qx-937-049-C.lbl
   Part No: 6Q1 937 049 D
   Component: 0000 BN-SG.         1S34  
   Coding: 09406
   Shop #: WSC 31414  
   VCID: 3C7CFC662C1240F83D4

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
   Part No: 1C0 909 605 K
   Component: 18 AIRBAG VW51 0P   0008  
   Coding: 12600
   Shop #: WSC 31414  
   VCID: 2C5CCC26DC72D078AD4

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 6Q0-920-xxx-17.lbl
   Part No: 6Q0 920 922 F
   Component: KOMBI+WEGFAHRSP VDO V19  
   Coding: 01468
   Shop #: WSC 00014  
   VCID: 356AE9420F3891B0C2A
   WVWZZZ9NZ5D023423     VWZ7Z0D0274798

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: 001K GATEWAY CAN    1S34  
   Coding: 00014
   Shop #: WSC 31414  
   VCID: F0E49856B0DA749851C

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 6Q0-423-156.clb
   Part No: 6Q0 423 156 AB
   Component: LenkhilfeTRW        V270  
   Coding: 00140
   Shop #: WSC 31414  
   VCID: 6FE61B2A2DE4EB60C86

No fault code found.

-------------------------------------------------------------------------------
Address 45: Inter. Monitor        Labels: 6Q0-951-171.lbl
   Part No: 6Q0 951 171 
   Component: Innenraumueberw.    0019  
   VCID: EFE69B2AADE46B60486

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels: 6Q0-959-433.lbl
   Part No: 6Q0 959 433 E
   Component: 4U Komfortgerát     0002  
   Coding: 00066
   Shop #: WSC 31414  
   VCID: 3D7AF162370849F00AA

   Subsystem 1 - Part No: 6Q1959801A
   Component: 4U Tõrsteuer.FS TFK 0004  

   Subsystem 2 - Part No: 6Q1959802A
   Component: 4U Tõrsteuer.BF TFK 0004  

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1J0-035-18x-56.lbl
   Part No: 6N0 035 186 B
   Component:  Radio BNO         0006  
   Coding: 06403
   Shop #: WSC 31414  
   VCID: 2D5AC122E768D970BAA

No fault code found.

End   ---------------------------------------------------------------------
 
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   #2  

Uwe

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Have you tried rotating glow plugs between cylinders to see if the problem moves with a specific plug?

Glow plug harnesses from back then were problematical at times...

-Uwe-
 
   #3  

andythechief

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Hi Uwe,

all sorted thanks; you were spot on.

I kept digging and found the following from Wingnut prior to doing some more testing:

http://forums.tdiclub.com/showthread.php?t=79819


Problem was isolated as follows:

Tested glow plug resistances- all ok at 0.3 ohms

Tested resistances from glow plug relay to wiring harness ends WHEN PROBED INTO THE GLOW PLUG END, PUSHING AGAINST WIRE END - all ok being equal and very low

Tested resistances from glow plug relay to wiring harness ends WITH GLOW PLUGS IN - not ok. Two were fine and comparable, two failed the 'wiggle and twist' test so connectors attaching to the glow plugs are corroded/faulty.

New 4 wire harness on order. Soldering iron at the ready.

Hope this helps someone else too.

Andrew
 
   #4  

Danners74

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Hi Uwe,

all sorted thanks; you were spot on.

I kept digging and found the following from Wingnut prior to doing some more testing:

http://forums.tdiclub.com/showthread.php?t=79819


Problem was isolated as follows:

Tested glow plug resistances- all ok at 0.3 ohms

Tested resistances from glow plug relay to wiring harness ends WHEN PROBED INTO THE GLOW PLUG END, PUSHING AGAINST WIRE END - all ok being equal and very low

Tested resistances from glow plug relay to wiring harness ends WITH GLOW PLUGS IN - not ok. Two were fine and comparable, two failed the 'wiggle and twist' test so connectors attaching to the glow plugs are corroded/faulty.

New 4 wire harness on order. Soldering iron at the ready.

Hope this helps someone else too.

Andrew

Its true what UWE said about the harnesses or contact bridge as its known. BERU are usually standard fit but with VW logo and writing on. You can get direct BERU fit from factors. About what you got for ohms readings max about 1 ohm depending on ambient temp. I do have a TPI for said repair instructions.
PLEASE though, buy the proper heatshrink crimp connectors for this repair not the soldering iron. Blue ones should be the correct diameter (opaque). I know the solder is cheaper, but the heat shrink is a better more durable repair.

Hope it helps and good luck :thumbs:

Danners
 
   #5  

andythechief

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Hi Danners,

thanks- I'm all ears! Where can I find your TPI? Can you share a link for the heatshrink crimp connectors you know are decent quality? I would always use heatshrink over a soldered joint anyway, but it's pretty tight space wise so would be great to just 'crimp and cook' so to speak.

I've not looked too much as to where the 4 wire harness routes to the relay but as the wire colours do not match at each end, I am guessing there is a connector somewhere under it all which currently is behaving itself ok. I was just going to snip the harness as close to the moulded part which goes onto the glow plugs but if the loom plug or connector can be accessed without too much trouble, it might be just as easy to conduit and clip a whole new harness in. Thoughts? Not sure what length/connector combination comes from VW yet.

Andrew
 
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