ABS coding problem, T4 TDI swap

Josh @ Huber Automotive · Feb 12, 2018

Hello,

I am swapping a European 5cyl TDI (engine code AJT) into a U.S. Eurovan. It was originally a VR6 AXK with an auto trans. The cluster, immobilzer, and key pill were swapped to match the ecu. It's running great on diesel now, and control units are mostly happy except for ABS. I need the correct login and coding for the ABS system with EPC. I can get PR numbers for either vin if needed. Any help would be greatly appreciated.

vin for the VR6 van: WV2KB47002H067736

vin for the TDI van: WV1ZZZ70Z3H101278

Code:

Monday,12,February,2018,11:51:54:45387
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 18.1.0.2 (x64)  HEX-NET CB: 0.4411.4
Data version: 20180122 DS285.1
www.Ross-Tech.com


VIN: WV1ZZZ70Z3H101278   License Plate: 
Mileage: 312980km-194476mi   Repair Order: 



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


Chassis Type: 70 (7D - VW Transporter/Multivan (1996 > 2004))
Scan: 01 02 03 08 15 17 18 19 22 25 35 37 56
 
VIN: WV1ZZZ70Z3H101278   Mileage: 312980km-194476miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: Redir Fail!
   Part No: 074 906 018 AK
   Component: 2,5l R5 EDC 0000SG  3905  
   Coding: 00002
   Shop #: WSC 02757  
   VCID: 5F8E493ADF8CD7BDEC-4B7A
   WV1ZZZ70Z3H101278     VWZ1Z0B2287967

2 Faults Found:
17849 - EGR Valve (N18) 
            P1441 - 35-10 - Open Circuit or Short to Ground - Intermittent
19561 - Valve for Intake Manifold Flap (N239) 
            P3105 - 35-10 - Open or Short to Ground - Intermittent
Readiness: N/A

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 7D0-907-379.lbl
   Part No: 7D0 907 379 E
   Component: ESP 5.3 T4 FRONT    V37  
   Coding: 06732
   Shop #: WSC 12345  
   VCID: 3326F58A038423DD78-5160

4 Faults Found:
18256 - Please check DTC Memory of Engine Controller 
            P1848 - 35-00 - 
00526 - Brake Light Switch (F) 
            36-00 - Open Circuit
01203 - Electrical Connection between ABS and Instrument Cluster 
            31-00 - Open or Short to Ground
01044 - Control Module Incorrectly Coded 
            35-00 -  - 

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: None
   Part No: 7D0 907 040 
   Component: CLIMATRONIC         0004  
   Coding: 00032
   Shop #: WSC 02743  
   VCID: 5F8E493ADF8CD7BDEC-25B6

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1J0-909-60x-VW3.lbl
   Part No: 1J0 909 603 BM
   Component: AIRBAG VW3 -        V04  
   Coding: 16973
   Shop #: WSC 02743  
   VCID: 75A20B924D707DED96-4B7A

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 7D0-920-xxx-17.lbl
   Part No: 7D0 920 903 B
   Component: T4-KOMBIINSTR. VDO V26   
   Coding: 01252
   Shop #: WSC 02743  
   VCID: 240406D6B66AB465F1-5160

1 Fault Found:
01316 - ABS Control Module 
            49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00002
   Shop #: WSC 02743  
   VCID: 70AC3A86321258C545-5160

1 Fault Found:
01316 - ABS Control Module 
            49-10 - No Communications - Intermittent

-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 6X0-953-257.lbl
   Part No: 6X0 953 257 
   Component: IMMO                0008  
   Coding: 00001
   Shop #: WSC 00000  
   VCID: 7DB213B2754025ADDE-4B3C
   WV1ZZZ70Z3H101278     VWZ1Z0B2287967

No fault code found.

-------------------------------------------------------------------------------
Address 35: Centr. Locks        Labels: 7D0-959-800.lbl
   Part No: 7D0 959 800 C
   Component:    Funksteuergerát  0001  
   Coding: 00001
   Shop #: WSC 02743  
   VCID: 2D12E3F2E5A0752D2E-4B3C

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1J0-035-18x-56.lbl
   Part No: 1J0 035 180 B
   Component:  Radio DE2         0005  
   Coding: 09400
   Shop #: WSC 02743  
   VCID: 1E70343E98069EB5A7-51F2

No fault code found.

End----(Elapsed Time: 02:27, VBatt start/end: 14.4V/14.4V. VIgn 0.0V)------

iichel · Feb 12, 2018

can you retrieve the coding from the donor cars ABS?

Josh @ Huber Automotive · Feb 12, 2018

Thanks for the quick response. I'm doing the swap for a customer and he got the parts. I understand he bought this stuff from a salvage yard in UK. It's a good idea so I will pursue it, but I'm not expecting much.

Uwe · Feb 12, 2018

I have a fuzzy recollection that the old Bentley CD or paper manual for the Eurovan had a fairly comprehensive login/coding table for the ABS modules used in these vans -- far more comprehensive than it needed to be for the NAR market. Unfortunately, I can't find either one anymore.

I've gone looking (via Google) for both the ECU and the ABS part numbers. Both seem rather rare and I can't find a single scan with that ECU part number that also shows the ABS. :cry:

-Uwe-

Josh @ Huber Automotive · Feb 12, 2018

I checked it out through erwin and there is a bit more than what is needed for NAR market. There is only two engine codes listed: AXK and ACV. I tried the closest ones for ACV. (you can see in the autoscan) It accepts but still throws the "incorrect coding". I have Parts Link 24 which shows that EPC could have been an option under the TDI vin. Do you think the paper manual has more than erwin?

Uwe · Feb 12, 2018

Well, I did say my memory of this is somewhat fuzzy, but VW has been known to strip stuff out of the manuals over time that isn't "necessary" in their view.

-Uwe-

Josh @ Huber Automotive · Feb 15, 2018

I realized that if I unplug the ecu the "incorrect coding" fault disappears in the ABS. Is it safe to assume that the ecu has everything to do with the ABS unit accepting the coding? The charts list coding by the pr code options, but the ABS system couldn't know if you got the pr codes correct. I'm thinking about making a list of all the coding option that I found so far, and posting it for other's reference. Unless someone knows of a place such a list has already been created.

Uwe · Feb 15, 2018

Yes, there's some kind of hand-shake between the ABS and the ECU.

-Uwe-

iichel · Feb 15, 2018

I could imagine, for example, a different build-up of brake booster vacuum between a petrol and diesel engine could already confuse an ABS.

Jetta 97 · Feb 18, 2018

The problem is that NAR Euro van came with only Petrol engine and Auto transmission, and ABS software was never meant to be for TDI.
So I doubt even if you have right coding you will be able to re code ABS module.

I know someone who put Manual transmission in VR6 Euro van and never was able to re-code ABS for manual transmission.

dieseldub · Sep 12, 2018

Been slowly picking away at an ALH swap into a Eurovan myself.

First off, there are 3 wires to the Eurovan instrument cluster from the ABS module that the Mk4 cluster has no provision for. The ABS will be permanently upset about that and light the cluster up. I sent the mk4 cluster and original Eurovan cluster to Clusters by Litke and had him swap the TDI tach face (which, handily also has the glow plug light cutout) and re-program the chip that controls the stepper motor for the tach so it would be correctly calibrated for the new tach face. Unfortunately, the trouble lights being all sent by CAN from ECU, the signal from the ECU to light the GP light via CAN does not trigger the bulb. So, I had Matt wire that bulb manually to T32/13, which is how it would be wired on a pre-CAN bus 99.5 cluster.

Handily, despite the fact that both CEL and GP lights are sent via CAN, EDC15 ECUs still have individual wire outputs for the trouble lights (among other things). And also handily, they're already wired to the plenum connector station, just with nothing on the body side to pick up the signals.

So, using both the 99.5 wiring diagram and the 2001+ diagram, I found the same color wire (that's all it took--matching by wire color) and routed it to the instrument cluster T32/13. Voila, now my hacked Eurovan cluster has a working glow plug light sent manually instead of by CAN.

Unfortunately, it's still lit up like a Christmas tree. The ABS is still unhappy and tells me to check the engine control module for codes, it also says it is incorrectly coded.

The engine control module has a code stored for missing message on the data bus from the air bag module, which of course it wouldn't see it via CAN, the Eurovan air bag module isn't on CAN...

Anyway, attached is a link to official VW repair manual for Eurovan ABS OBD (hopefully you have a TDIClub login). It includes tables for login and recoding. Unfortunately, no matter what I try, it just automatically resumes to the original coding and still has a code stored for incorrect coding in the ABS module.

I also did find that VCDS had a coding suggestion in the engine computer for no crash data, which I was thinking maybe that would make it stop looking for a message from the airbag controller via CAN. Unfortunately, that coding won't save either (GN suffix ALH ECU, currently coded 00002 for manual, VCDS suggested a possible coding of 00005 for manual transmission w/o crash recognition).

So, here I am pulling my hair out with an instrument cluster lit up like a Christmas tree after all that. Hopefully the coding information will at least help the OP with his ACV swap.

Guess I'll at least ping Malone to see if he can find a way to code out the need to see air bag info and have better compatibility with the ABS unit.

Here's the PDF for login and coding the Eurovan ABS/ESP module: http://pics.tdiclub.com/data/500/D3E800B99CF-Brake_System_On_Board_Diagnostic.pdf

dieseldub · Sep 12, 2018

No sooner do I say that, but I actually get a coding change to accept. Unfortunately, ESP, ABS etc lights are still on and code still stored for incorrect coding and check ECM for codes.

In case it helps you, though: the original coding for the Eurovan I'm working on:

06639.

Looking it up in the tables, that came out as a short wheel base, lowered suspension with 16" wheels. There is also a PR code attached, but you will see that PR code repeat a lot with a lot of different coding options, so I paid little attention to it. And of course it was originally an AXK engine with automatic.

The coding for ACV with manual, also short wheel base, lowered suspension and 16" wheels:

06733

And first you must login using 07763

Hopefully that works for you. For me, looks like I either put up with it or plead for help from someone who can better hack these modules than I can.

BaraJag · Jun 27, 2023

dieseldub said:
Been slowly picking away at an ALH swap into a Eurovan myself.

First off, there are 3 wires to the Eurovan instrument cluster from the ABS module that the Mk4 cluster has no provision for. The ABS will be permanently upset about that and light the cluster up. I sent the mk4 cluster and original Eurovan cluster to Clusters by Litke and had him swap the TDI tach face (which, handily also has the glow plug light cutout) and re-program the chip that controls the stepper motor for the tach so it would be correctly calibrated for the new tach face. Unfortunately, the trouble lights being all sent by CAN from ECU, the signal from the ECU to light the GP light via CAN does not trigger the bulb. So, I had Matt wire that bulb manually to T32/13, which is how it would be wired on a pre-CAN bus 99.5 cluster.

Hey there, what was the end result of all these efforts, did you ever figure anything more out?
Also what year model was the Eurovan?

ABS coding problem, T4 TDI swap

Josh @ Huber Automotive

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iichel

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Josh @ Huber Automotive

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Uwe

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Josh @ Huber Automotive

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Uwe

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Josh @ Huber Automotive

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Uwe

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iichel

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Jetta 97

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dieseldub

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dieseldub

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BaraJag

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