ZV Hecktuer - known weaknesses?

Hello everyone,

"Today, while unloading my groceries in the intense heat (around 34 degrees Celsius), I pressed the button for the central locking system while standing behind the car. The sound was different than usual (as if the servo motor wasn't running properly). In fact, the rear door wasn't locked. I then experimented a bit with the manual locking mechanism and the central locking system until I heard the servo motor again... but it sounded strained, as if it was working against resistance or not having full power." It couldn't be repeated, so I had to manually lock it instead.

Just now, I took it apart and analyzed it. Whoever came up with the design for the tailgate cover attachment on the Ibiza 6K GP01 should be ashamed. It's not that the metal clips come loose where they're supposed to; no, they break off where they're actually supposed to stay attached to the cover, and even with pliers, it's difficult to remove the clips themselves. Anyway, I managed to remove the trim enough to access the locking mechanism, and I was able to lubricate it – my theory was that the extreme heat (the car was facing the sun this morning, and the lock was so hot you could barely touch it) was making the part difficult to operate.

After that, I tested it... it was a bit easier to do manually, but it was impossible to get the servo to activate using the central control unit - I couldn't find a way to trigger it.

Since I also didn't have any more time and still needed some information, I stopped working on it for now. I'd like to ask a few questions to the group, because my main problem is that there's a half-hour drive between here and my crafting space, and crafting on the road isn't really enjoyable. Furthermore, this is the first time I'm handling a case like this.

This is an electromechanically actuated lock, not pneumatic, as is often the case with VW. It consists of the actual lock, to which a servo motor is connected from below via a rod. This servo motor engages or disengages a lever that is used with the external handle to unlock the door. Manually, you can move this rod using a key, and the servo motor can be felt rotating. The mechanism is easy to operate, except perhaps for the servo motor itself, but it's not designed to be externally actuated. A two-wire cable connects to the servo motor, which I haven't measured due to time constraints. Since the servo needs to rotate from the neutral position in both directions (which is how you manually operate it), I suspect that it can simply be controlled by reversing the polarity of the power supply (although I haven't tested this yet, as I want to be sure that there's no sensitive electronics inside that could be damaged).

Well... does anyone know anything about these things?

What are the weaknesses here? Servo or rather, the mechanics?

Are there any microswitches in the castle (the idea came to me only after assembling it during the return trip, so I couldn't check it) that inform the control system about the current position of the servo? If that's the case, and they're not working properly, it would explain it.

Can the servo simply be powered with 12 volts using alternating polarity?

How is it typically navigated in normal circumstances?

What else could cause the servo to not work?

By the way, there's no error memory or anything like that; the central locking system isn't connected to the K-bus in the 6K model (we discussed this a long time ago regarding the auto-lock function). Therefore, a diagnostic check of the actuators, which could provide useful information, is also not possible.

When I'm crafting next time, I want to measure what voltage reaches the servo, test its function as much as possible, and ideally, fix any issues right away } - that's why I'm asking about any known weaknesses.

Thank you very much and best regards,

Jan.

P.S.: @Ulf... this wouldn't have happened without the central ventilation system.

Quote:

It was impossible to provoke the servo to activate.

Check if power is reaching the device. If so, replace the actuator motor. This part costs less than 15 euros. It may also be available through "Freundlichen."
I once fixed something like that --> it was a real challenge.

Jan6K wrote:

P.S.: @Ulf... this wouldn't have happened without the ZV.

Hi Jan,

Why can you read my thoughts before I have written them?

Did you know that my Peugeot 205 (the predecessor to the G3) almost caught fire once because of the factory-installed central locking system?
One servo motor had failed to de-energize after the last locking sequence and was drawing a short-circuit current, causing its plastic housing to begin to overheat.
The factory-installed fuse in the central electrical system might have smirked wearily at the situation, but it didn't blow – instead, the motor winding burned out, fortunately before the plastic casing around it caught fire.

My decision was clear: I got rid of the remaining parts of the old TV, including the still-functional electronic housing (which presented an opportunity), selling everything through the local classified ads... and from then on, I would avoid "lazy comfort electronics" as much as possible.

Our Seat dealer looked somewhat bewildered when we asked him to remove the standard elFH (electric folding mirrors), central locking, and electrically adjustable mirrors before we took delivery of the new car back then... see above. The opportunity is now available for you as well.

Did we have a 01 Toledo yesterday? The part is actually as cheap as BlechMann says. So it doesn't seem to be that rare.

Hi,

Great, thanks for your answers. Then I'll just buy one of those servos, even though I'm doing it without disassembling it again beforehand.

So, there are no microswitches or similar sensors on the lock, correct?

@Ulf: We're lazy... and a radio-controlled gate opener is so great when it works (which it did for 5 years).

Best regards,

Jan.

Jan6K wrote:

So, there are no microswitches on the lock or anything like that, right?

There are definitely some in the doors. I know this because Seat-Fritze had left the door lock mechanisms loose; they are integrated with the actuator motors.

The Sevomodule is likely located separately in the tailgate, and he had removed it. Still, I suspect there's a switch involved.

Quote:

and a radio-controlled gate opener is so great when it works (which it did for 5 years).

If you mean... in any case, you've missed the opportunity to sell Ibi at the right time, so that you wouldn't have any trouble with it .

Hi,

Quote:

The Sevomodule is likely located separately in the tailgate, and he had removed it. Still, I suspect there's a switch involved.

Yes, it's separate. More precisely, it's installed about 10 cm below the lock and operates it via a thin metal rod. If there are any microswitches inside the servo itself, then replacing it would automatically solve the problem... but it wouldn't be ideal if it's only in the lock mechanism.

Quote:

If that's what you mean... in any case, you've missed the opportunity to sell the Ibi at the right time, so that you wouldn't have any trouble with it.

"Annoyance" is not a word I would use to describe this, especially since all the essential components are working perfectly. Spending one day tinkering with it is worth the comfort provided by the central locking system. Furthermore, 76,000 km (approximately 47,000 miles) is absolutely not a high mileage for a TDI engine that is just under five years old, and it's not something to worry about in terms of major defects.

Best regards,

Jan.

Hi again,

Addition to the microkeyboard section:

Of course, the side doors need something like that so that the central locking system can detect when they are being manually unlocked and ensure that it also unlocks the other doors. I don't know if this function exists for the rear door... I've never manually unlocked it when the central locking system was working .

I was actually thinking of using microswitches to determine the end positions of the servos, but those are probably much simpler to integrate than attaching them to the lock itself.

Well... if it's really the servo, I'll take it apart then.

Best regards,

Jan.

Jan6K wrote:

Spending one day a week crafting is worth the comfort provided by the central locking system.

If that's your financial situation, and you're facing a fire hazard (as mentioned above),... Example) If you choose to ignore it, then so be it...
For me, in the event of a central locking system failure, another disadvantage would be having to conduct a "trust round" around the car every time after locking it, to check if everything is actually locked, because there's no reason why a part that fails after 5 years with you wouldn't fail on another car much sooner. Want to mess around?
Or do you think that any insurance company would, for example, pay for a radio that was stolen from a car if a malfunctioning central locking system (ZV) practically invited the thief in (and there are certainly buyers for the radio, MFA, climate control unit of the 6K, especially since these things often break down )?

Quote:

Furthermore, 76,000 km for a TDI engine that is just under five years old is absolutely not a high mileage, and one should not start thinking about major defects.

While it might not be the case for the engine itself, it certainly applies to the features and extras, as your experience demonstrates. And for me, the highest possible overall reliability of a car is more important than ultimate comfort.

I'm sorry, but in situations like this, I simply can't resist the urge to demonstrate my views "through example," just to encourage a few people to think things over.

Hi everyone,

"Since yesterday, my rear door central locking system has a new servo motor (costing about 12 euros), and it's working perfectly again. The old one would sometimes work again temporarily, especially when it was cooler, but this way it's more reliable. I'll remove the old one sometime later... maybe I'll find some visible problem areas." Currently, and based on a comparison with the new model, I suspect there's an internal mechanical issue.

Best regards,

Jan.

Hi,

I've analyzed the modified servo, and it seems to have a problem with the motor's carbon brushes, as it sometimes works when power is applied, and sometimes it doesn't.

The internal mechanism is disturbingly simple... A cheap motor, plastic gears, and a worm gear with a high pitch, allowing the device to be operated "in reverse" by simply turning the key.

By the way, there are no limit switches (or similar devices). Continuous operation would likely cause the motor windings to burn out eventually, because the device is mechanically blocked at its limit.

Here's a picture of this marvel of technology... it's definitely not worth the 12 euros I paid for it.

Best regards,

Jan.

Hi,
That's almost exactly like the servo motors used for the climate control system in the A6. Just so that you're aware, it's not something you can participate in with just 12 euros .
However, (I haven't tried this myself) replacement charcoal from the Märklin model train shop is supposed to fit...

Best regards from Berlin.
olli