Facelift Conversion Problems: ESP, Central Locking, Instrument Cluster

Hello,

Last week, I installed a complete technical package from a 2003 Audi A3 1.9 TDI with an ASZ engine and a 6-speed gearbox into my A3 8L, 1.9 TDI with an AHF engine (built in June 1999). I had problems with the gearbox in the 5th gear, and I was simply intrigued by the idea of the conversion.

The entire wiring harness, including control units, engine, and transmission, was replaced. In short, everything was changed except for the body and chassis. The wiring harnesses for the doors were also not transferred over.

The donor vehicle had an accident on the driver's side, and the airbags were deployed. Therefore, the airbag control unit was also replaced with a used one that had not been deployed (the coding from the old unit was transferred to the new one).

Since I have an external audio system in the car, the cables for the speakers and the wiring to the Nokia subwoofer, etc., have been removed from the car's wiring harness. Only the black 8-pin connector for supplying power to the radio, the antenna cable, and the red ISO connector remain.

In addition, the wiring harness was reduced from the 5-door version to a 3-door version (the rear doors were only wired to the front doors and could be relatively easily removed).

However, the wiring harness for an electric sunroof was still installed.

The donor vehicle, or my car, now has a parking assist system (the control unit is not connected, as it is not needed) and a phone preparation system (also not connected). However, this should not be related to my problems.


Furthermore, I can say that the engine is running and the car drives (currently without the intercooler, as it still needs some optimization). This is why there are error messages for intake manifold pressure and temperature in the engine control unit. Currently, the rear hatch is missing, which means the wiring harness for the rear hatch is loose and unconnected inside the car.

I have already checked the continuity of the Low/High CAN lines from the KI (instrument cluster) to the ABS/ESP control unit and the engine control unit. When the ignition is switched on, there are approximately 2.3 to 2.6 volts between each line and ground.

Unfortunately, I don't have much experience when it comes to the "Can" thing.

I have attached the error log to this email.

I am encountering problems with the entries in the central control unit, the dashboard panel, and the ABS control unit.

Regarding this issue, I can say that the error code in the central locking control unit can be cleared. However, after a short time, the central locking pump briefly activates, and the error code reappears.

The "Corporate Data Bus Fault" error can also be cleared, but it reappears after a short time.
As far as I could tell from the wiring diagrams, I only see the two corporate data bus lines from the instrument cluster to the radio connector, which are currently disconnected. (But that shouldn't be a problem, since they essentially function as disconnected even when the radio isn't connected?)


Sunday, June 4, 2017, 12:59:27:04527
VCDS, a Windows-based VAG/VAS emulator, runs on Windows 8.1 x64.
VCDS Version: RKS 17.1.3.0
Data as of: 20170224 DS267.4
http://shop.dieselschrauber.de


Vehicle Identification Number: WAUZZZ8L83A070907
License plate: CHA A255
Mileage: 209,210 km. Repair order:



"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."


Vehicle type: 8L (8L - Audi A3/S3 (1997 > 2005))
Scan: 01 02 03 08 15 16 17 22 35 37 45 55 56 57 75 76

Vehicle Identification Number: WAUZZZ8L83A070907
Mileage: 209,210 km
"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 01: Engine Control Module
Label file: DRV\038-906-019-ASZ.lbl
Part number: 038 906 019 FT
Component: 1.9L R4 EDC G000SG 1577
Encoding: 00002
Operating number: WSC 06435
VCID: 6ED7B7AC2A86AA310B-4B18
WAUZZZ8L83A070907 AUZ5Z0C0147051

2 error codes found:
17569 - Intake air temperature sensor (G72).
P1161 - 35-00 - Open circuit/short circuit after positive terminal.
17564 - Intake manifold pressure sensor (G71)
P1156 - 35-10 - Short to ground / Open circuit - Intermittent.
Readiness: 0 0 X X X

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 03: Brake Electronics
Label file: DRV\1C0-907-37x-ESP-F.lbl
Part number: 1C0 907 379 M
Component: ESP FRONT MK60 0102
Coding: 0019458
Operating number: WSC 06435 000 00000
VCID: 346365C4542AC0E13D-515A

"One error found:"
01314 - Engine Control Unit.
013 - Please read the error memory.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 08: Climate Control/Heating. Label file: DRV\8L0-820-043-1D.lbl
Part number: 8L0 820 043 H
Component: A3, CLIMATE CONTROL UNIT, 0105.
Encoding: 00041
Operating number: WSC 00656
VCID: 2D5570A0E700912972-259E

"One error found:"
00787 - Temperature sensor, fresh air intake duct (G89).
29-10 - Short circuit to ground - Intermittent.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 15: Airbag
Label file: DRV\8L0-959-655-AI8.lbl
Part number: 8L0 959 655 J
Component: Front and side airbag 4008.
Encoding: 00104
Operating number: WSC 06435
VCID: 458528005FB049699A-5178

No error codes found.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 17: Control panel module
Label file: DRV\8L0-920-xxx-17.lbl
Part number: 8L0 920 900 K
Component: COMBINATION INSTRUMENT + TRIP COMPUTER. M73 D05.
Encoding: 04040
Operating number: WSC 00050
VCID: 336166D80124C7D924-4B18
WAUZZZ8L83A070907 AUZ5Z0C0147051

"One error found:"
01336 - Corporate Data Bus Comfort.
37-10 - defective - intermittent.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 35: Central Locking
Label file: DRV\8D0-862-257.lbl
Part number: 8LO 862 257 D
Component: Central locking pump, radio. D03.
Encoding: 12864
Operating number: WSC 65535
VCID: 55A5F840AF10F9E9EA-4F02

"One error found:"
01366 - Opening via crash signal.
35-00 - -

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 76: Parking Assist
Label file: DRV\4B0-919-283.lbl
Part number: 4B0 919 283.
Component: Parking system A3 RDW D18.
Encoding: 00103
Operating number: WSC 06435
VCID: 66C7CF8C0276627173-520C

"One error found:"
01543 - Parking assist warning buzzer (H15)
31-00 - Short circuit to ground / Interruption.

End----------------------------(Duration: 03:3-----------------------------

Quote:

17569 - Sensor for intake air temperature (G72) P1161 - 35-00 - Open circuit/short circuit after positive terminal. 17564 - Intake manifold pressure sensor (G71) P1156 - 35-10 - Short to ground/open circuit - Intermittent

It is either located in a plastic tube between the air filter housing and the intake manifold, similar to the AHF, or directly in the air filter housing. The sensor used in the ASZ is a different type with a different measurement range.

Best regards, Rainer.

dieselschrauber wrote:

... It is either located in a plastic tube between the air filter housing and the intake manifold, similar to the AHF, or directly in the air filter housing. The sensor used in the ASZ is a different type with a different measurement range. Best regards, Rainer

No, it doesn't seem to be mounted at all...

Quote:

Furthermore, I can say that the engine is running and the car is driving (currently without the intercooler, as it still needs some optimization). This is also why there are error codes for intake manifold pressure and temperature in the engine control unit.

Okay, now let's talk about your sloppy work .

Quote:

I am encountering problems with the entries in the central control unit, the dashboard panel, and the ABS control unit.

The error in the central locking control unit (ZV STG) is triggered by a crash event. Something indicates to the system that there has been an "accident," and as a result, it initiates an emergency unlocking.

The error in the AI is incredibly simple...

Quote:

As far as I could tell from the wiring diagrams, I only see the two corporate data bus lines from the instrument cluster to the radio connector, which are currently disconnected. (However, this shouldn't be a problem, as they essentially function as disconnected even when the radio isn't connected?)

...and you're saying that's enough to prevent the AI from searching for the car radio?
Unfortunately, that's not enough; you still need to tell the AI that there is no longer a built-in car radio.

The ABS error will disappear if the MSTG is also functioning correctly.

"I understand the errors in the engine control unit; the sensor is also not currently installed. The engine has only been started for testing purposes without the intercooler. I am aware of these errors, and they should disappear after the intercooler and/or the sensor is installed."

The sensor will eventually be replaced with the original one from the ASZ engine, which will ensure that the readings are accurate again.

However, the errors found in the engine control unit so far don't actually relate to the ABS or ESP systems. I don't think the ABS control unit would be interested in the intake air temperature or pressure.

But am I correct in my assumption that the "Comfort" bus is only responsible for the radio? ...and therefore cannot have any impact on the other errors?

Regarding the crash signal error: Currently, the entire wiring harness for the tailgate is not connected. Is it possible that the control unit is simply missing the contact for the microswitch in the tailgate?

Andreas_M wrote:

... I don't think the ABS control unit is interested in the intake air temperature or pressure. ...

Ah, so you believe that the ESP/ASR can calculate the load state of the engine without functioning engine electronics...? ... Well then...

Your ASR (which is integrated into the ABS) will only function with a working engine control unit. The error message in the ABS control unit doesn't provide any more information than that.

Quote:

But am I correct in assuming that the "Komfort Bus" is only responsible for the radio?

No, that also includes central vehicle functions and various other comfort features.

Quote:

...and therefore cannot have any impact on the other errors?

At least not regarding the MSTG/ABS error.
However, that's already a ZV error.

Quote:

Regarding the error with the crash signal: Currently, the entire wiring harness of the tailgate is not connected. Is it possible that the control unit is simply missing the contact from the microswitch in the tailgate?

As far as I can tell, you've left out even more control units.
Have you also informed the vehicle electronics system that these parts are no longer installed?
Okay, for example, the sunroof control unit (STG). In newer vehicles, there's an emergency opening mechanism installed there. This could report an error and be responsible for the crash notification. The missing tailgate should actually be reported as an error in the central locking system. That would make me suspicious.

That makes perfect sense...

I just plugged in the sensor, and the ESP error has now disappeared. ...sometimes, you just need a little nudge .

Due to the issues with the ZV (central locking) and the comfort bus, I will probably have to sit down at the tablet now .

The radio has now disappeared from the encoding.

I'm still having the problem with the central vacuum pump.

Unfortunately, the pump in the donor vehicle was damaged in the accident. A different pump with a different part number was installed. To my knowledge, these are the same (except for the radio/alarm system). Or am I misinformed about that?

Andreas_M wrote:

... A different part, with a different part number, was installed. ...

The fact that this software barely seems to fit in with the rest could already be the problem.