Patil's little Polo 6R 1.2 Tsi Dsg7 RHD

[ciclo]

Oh my ... very bad news, the damage is very serious.

It is absolutely necessary to remove the dashboard and check meticulously (with magnifying glass) for damage in the wires that run alongside the two burnt wires inside of original harnesses.
To do this, the original cloth tape must be removed from the original harnesses, with surgical precision to avoid cuts in the original wires.

The two burned wires, which are no longer functional, and now completely stripped, must be cut to avoid future problems.

This should be your number 1 priority if you want to safely use the car again. At this time your safety is not guaranteed if you drive the car in that state (without check for damage).

The car could catch fire spontaneously.

Do not use the car, remove the battery ground wire.

---
You can make some preliminary checks in the original harness that reaches the T17 connector. Remove the original cloth tape as far as possible to check for damage to all wires that reach the T17 connector.

Remember the burnt yellow wire only goes from the T17/7 connector to the relay holder.

My concern in this matter is absolute at this time.

[patil]

Ok Master, I can understand the gravity of the damage happened. I will take up the clean up job as soon as possible.

Any idea where the brown ground goes and connects?

Yes, I won't use the car, unless it is fully sterilised and safe to use again.
Thanks a lot Master for your deep concern, I will fix it up.
I will report back to you once the work begins.

[ciclo]

Any idea where the brown ground goes and connects?

Earth connection in main wiring harness
- There are no specified connection points for all ground wires inside the harnesses.
- Only the connection points to the chassis. For example https://drive.google.com/file/d/1tuLt2f ... sp=sharing (7)

[ciclo]

Something new?

[patil]

Hello Master, sorry I am busy with my work, and as it might take more time to fix, I have planned the clean up job on weekend.

The car is safely grounded.

Thanks for the wiring diagram Master.

Should I install new replacement wires or isolating and removing the burnt wires is enough?

Will keep updating... Master.

[ciclo]

The first thing is the thorough inspection of the all wires inside the original harnesses.
Due to how the current flows and how the temperature is transmitted it is possible that there is no damage to the wires inside the original harnesses, it depends on the heating time.
It must be verified in any case.

The section of any active wire inside harnesses that has damage to its insulation must be renewed, so that it can return to work within the recommended specifications (amperage, temperature, etc).
Take pictures and distances if you find these damages.

To avoid future problems, the both original burned wires (yellow and brown) should be cut.

---
All day with this image in my head ...

I wish it never happened to you.

[patil]

The first thing is the thorough inspection of the all wires inside the original harnesses.
Due to how the current flows and how the temperature is transmitted it is possible that there is no damage to the wires inside the original harnesses, it depends on the heating time.
It must be verified in any case.

The section of any active wire inside harnesses that has damage to its insulation must be renewed, so that it can return to work within the recommended specifications (amperage, temperature, etc).
Take pictures and distances if you find these damages.

To avoid future problems, the both original burned wires (yellow and brown) should be cut.

Aye Master, everything you said is cemented in my head. Will follow as advised with utmost care and precision.

I have called a VW technician to help me out, he obliged to come by my place and help me in clean up job over the weekend.

I will take a detailed pictures and post the results here. Thanks a lot for sending me a Tesa cloth tape, it will help.

All day with this image in my head ...

I wish it never happened to you.

The whole world will be laughing at my stupidity.

Showed this picture to my wife and said.. I broke the car. She couldn't believe it.

[ciclo]

The whole world will be laughing at my stupidity.

No. This can happen to anyone.

---
I have seen worse things from people who are supposed to be super specialists in these matters.
Well, you have a little reason, we laugh a little about it ... after the regrets.

[patil]

Update:

Master, the operation on my 6R was successful.

2 days of intense hard work paid off well with happy ending.

Both the burnt wires were traced to their full length and removed. The brown ground wire was connected to the factory ground wires twist within the main wiring harness.(pictures below)
Luckily no other wires in the vicinity of both burnt wires were damaged.





The blunder I did, I must say, was a blessing in adversity... I could able to reorganise the previously retrofitted wiring harnesses systematically. And also my new OEM retrofit was done at the same time(will talk about it later).

Few wonderful people helped me to finish off the clean up successfully and they deserve to be mentioned and credited.. My heartfelt thanks to Mr Jayaram , VW technician, he was star of the show and did most of the work. I also immensely thank our forum members Shakthi, Nikhil and Sheetal for dropping in at my place during ongoing work, and sharing their knowledge and experience. We chatted a lot and it was fun...

I also thank you Master, for expressing serious concern and pushing me to fix the issue on urgent basis. Rightful Master

Autoscan latest:

Code: Select all

Sunday,04,August,2019,20:45:33:09269
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 19.6.1.0 (x64)  HEX-V2 CB: 0.4508.4
Data version: 20190529 DS308.0
www.Ross-Tech.com


VIN: MEXL15606GT048293   License Plate: 


Chassis Type: 60-VW25 (7E0)
Scan: 01 02 03 04 08 09 10 15 17 19 25 37 44 5F 65 77

VIN: MEXL15606GT048293   Mileage: 43030km-26737miles

01-Engine -- Status: OK 0000
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
10-Park/Steer Assist -- Status: OK 0000
15-Airbags -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
37-Navigation -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
5F-Information Electr. -- Status: Malfunction 0010
65-Tire Pressure -- Status: OK 0000
77-Telephone -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CBZB)       Labels:. 03F-906-070-CBZ.clb
   Part No SW: 03F 906 070 KC    HW: 03F 907 309 AJ
   Component: SIMOS10.22AH10 6270  
   Revision: --H10---    Serial number: 00000000000000
   Coding: 00250056232400080000
   Shop #: WSC 53863 002 1048576
   ASAM Dataset: EV_ECM12TFS02103F906070KC 004006
   ROD: EV_ECM12TFS02103F906070FP.rod
   VCID: 6D84C0CEAD13BD3F11F-8038

No fault code found.
Readiness: 0110 0101

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 0AM-927-769.clb
   Part No SW: 0AM 300 065 N    HW: 0AM 927 769 D
   Component: GSG DSG AG7     431 6502  
   Revision: 00043014    Serial number: CU501508317273
   Coding: 0000020
   Shop #: WSC 01260 002 1048576
   VCID: 3A2E3B92A05DDA87C4D-806E

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 6R0-907-37x-ESP90.clb
   Part No SW: 6R0 907 379 BN    HW: 6R0 907 379 AS
   Component: ESP9.0i front H03 0001  
   Serial number: --------------
   Coding: 62DD2463422703C8461624724254C0800908
   Shop #: WSC 29230 002 1048576
   ASAM Dataset: EV_Brake1ESP90iBOSCH 003031
   ROD: EV_Brake1ESP90iBOSCH_003_VW21.rod
   VCID: 0B40AE56B3C7130FAFB-805E

No fault code found.

-------------------------------------------------------------------------------
Address 04: Steering Angle (G085)       Labels:* 6R0-959-654.clb
   Part No SW: 6R0 959 654     HW: 6R0 959 654 
   Component: LENKW.SENSOR  H07 0070  
   Serial number: 10051504650275
   Coding: 01
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_LWSKLOVW25X 005001
   ROD: EV_LWSKLOVW25X.rod
   VCID: 7EA6F782F07536A7B85-802A

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels: 6R0-907-044.clb
   Part No SW: 6R0 907 044 Q    HW: 6R0 907 044 Q
   Component: Climatronic   H12 0615  
   Revision: V0000000    
   VCID: 41DC4C7EC18B895F857-8014

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 7E0-937-BCM-V1.clb
   Part No SW: 7E0 937 090 D    HW: 7E0 937 090 D
   Component: BCM PQ25 Max4 H82 0762  
   Revision: B9082001    Serial number: 8601 222180475
   Coding: 3AB02BFF08A10000003800C07C2B9490D2C061FF608C0000200400020000
   Shop #: WSC 00046 123 12345
   VCID: 2C020DCA56097437461-8078

   Subsystem 1 - Part No SW: 6R0 959 802 BH    HW: 6R0 959 802 BH  Labels: 6R0-959-802.CLB
   Component: J386__TSG_FT  003 8612 
   Serial number: KU0KU015041441050460
   Coding: 1400B3

   Subsystem 2 - Part No SW: 6R0 959 801 BC    HW: 6R0 959 801 BC  Labels: 6R0-959-801.CLB
   Component: J387__TSG_BT  003 8612 
   Serial number: KU0KU014041441047765
   Coding: 0400B3

   Subsystem 3 - Part No SW: 6C0 959 442     HW: 6C0 959 442 
   Component: E221__MFL-TAT  H04 0019 
   Serial number: 1971517275001536AB2B
   Coding: 240000

   Subsystem 4 - Part No SW: 6R0 959 811 L    HW: 6R0 959 811 L
   Component: -------------  006 5550 
   Serial number: 13102580150623202239
   Coding: 020000

   Subsystem 5 - Part No SW: 6R0 959 812 L    HW: 6R0 959 812 L
   Component: -------------  006 5550 
   Serial number: 13202581150812164218
   Coding: 020000

1 Fault Found:
01504 - Bulb for License-Plate Light (X) 
            010 - Open or Short to Plus
             Freeze Frame:
                    Fault Status: 01101010
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Time Indication: 0
                    Date: 2019.08.04
                    Time: 20:43:44


-------------------------------------------------------------------------------
Address 10: Park/Steer Assist (J446)       Labels:| 7E0-919-475.clb
   Part No SW: 7E0 919 475 J    HW: 7N0 919 475 
   Component: PARKHILFE 8K  H06 0105  
   Revision: --------    Serial number: 28261224902578
   Coding: 308101
   Shop #: WSC 02756 790 50316
   ASAM Dataset: EV_VW75XParkAssis8K 001003
   ROD: EV_EPHVA18VW250GPCS_VW25.rod
   VCID: 392C249EA9DBD19FCD7-806C

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 6R0 959 655 J    HW: 6R0 959 655 J
   Component: VW10AirbagU06 H10 0020  
   Revision: --------    Serial number: 003GW0118WCJ
   Coding: 003036
   Shop #: WSC 01234 785 00200
   ASAM Dataset: EV_AirbaVW10BPAVW250 A01001
   ROD: EV_AirbaVW10BPAVW250.rod
   VCID: 49CC545EF93B411F5D7-801C

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 6RD 920 870 A    HW: 6RD 920 870 A
   Component: KOMBI         H05 0805  
   Serial number: 00000000000000
   Coding: 140C01
   Shop #: WSC 00046 123 12345
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04727
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW23.rod
   VCID: 47C85266EF2FB76F4B3-8012

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 7E0-909-901.clb
   Part No SW: 7E0 909 901     HW: 7E0 937 090 D
   Component: GW-K-CAN TP20 H82 0762  
   Revision: B9082001    
   Coding: 002304
   Shop #: WSC 00046 123 12345
   VCID: 688AB1DA82719817629-803C

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer (J334)       Labels:| 5K0-920-xxx-25.clb
   Part No SW: 5K0 953 234     HW: 5K0 953 234 
   Component: IMMO          H05 0805  
   Serial number: 00000000000000
   Coding: 000000
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03710
   ROD: EV_Immo_UDS_VDD_RM09.rod
   VCID: 6A8ECBD29CFDAA0774D-803E

No fault code found.

-------------------------------------------------------------------------------
Address 37: Navigation
Cannot be reached

-------------------------------------------------------------------------------
Address 44: Steering Assist (J500)       Labels:| 1Sx-909-144-44.clb
   Part No SW: 1S2 909 144 P    HW: 1S2 909 144 P
   Component: EPS_ECU       H61 1702  
   Coding: 0001000000000000
   Shop #: WSC 00000 000 00000
   ASAM Dataset: EV_SteerAssisNSK 014008
   ROD: EV_SteerAssisNSK_014.rod
   VCID: 41DC4C7EC10B895F857-8014

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794)       Labels:| 5G0-035-MIB-STD2.clb
   Part No SW: 5C0 035 680 B    HW: 5C0 035 680 B
   Component: MU-S-N-ER     H22 0252  
   Serial number: VWZAZ2R8949071
   Coding: 02630101FF00000011110001000808001F0100D4002001008F
   Shop #: WSC 00046 123 12345
   ASAM Dataset: EV_MUStd4CTSAT 001022
   ROD: EV_MUStd4CTSAT_VW37.rod
   VCID: 201AE9FA2A41A057EA9-8074

   Data medium: 
   Subsystem 1 - Part No SW: 5NA 919 866 A    HW: -----------
   Component: ECE2 2018/19  --- 1020 
   Serial number: --------------------

6 Faults Found:
1555 - Check Software Version Management 
          B201A 00 [009] - -
          [Check software version management]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:45

                    Voltage terminal 30: 13.4 V
                    Status_Software_Version_Management-module_name: 

15360768 - Component Protection 
          U1101 00 [009] - Active
          [Anti-theft protection - component protection active (0xEA6300)]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 4
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:45

                    Voltage terminal 30: 13.3 V

7194 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [Side assist (0x1A) - function restriction due to communication error - BapErr_retry not successful]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:47

                    Voltage terminal 30: 13.5 V
                    BAP-BAP_Function_ID: 02

7201 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [Road sign display (0x21) - function restriction due to communication error - BapErr_retry not successful]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:47

                    Voltage terminal 30: 13.5 V
                    BAP-BAP_Function_ID: 02

0001 - Antenna 1 for Radio 
          B1119 13 [009] - Open Circuit
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:45

                    Voltage terminal 30: 13.5 V
                    Status of antenna 1 for radio-Antenna current: 0 mA
                    Status of antenna 1 for radio-Connection between radio and antenna amplifier: Electrical OK
                    Status of antenna 1 for radio-Connection between antenna amplifier and antenna: Electrical OK
                    Status of antenna 1 for radio-Reception level antenna 1: 0 dBµV

0003 - Antenna 2 for radio 
          B111A 13 [009] - Open Circuit
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 45
                    Mileage: 43031 km
                    Date: 2019.08.04
                    Time: 20:43:45

                    Voltage terminal 30: 13.5 V
                    Status of antenna 2 for radio-Antenna current: 0 mA
                    Status of antenna 2 for radio-Connection between radio and antenna amplifier: Electrical OK
                    Status of antenna 2 for radio-Connection between antenna amplifier and antenna: Electrical OK
                    Status of antenna 2 for radio-Reception level antenna 2: 0 dBµV


-------------------------------------------------------------------------------
Address 65: Tire Pressure (J502)       Labels: 3AA-907-273.clb
   Part No SW: 3AA 907 273 F    HW: 5Q0 907 273 
   Component: RDKBERU30     H04 0011  
   Serial number: 40000000058983
   ASAM Dataset: EV_RDKBERU30 005005
   ROD: EV_RDKBERU30_005.rod
   VCID: 372822A69FCFC7EF3B3-8062

No fault code found.

-------------------------------------------------------------------------------
Address 77: Telephone
Cannot be reached

End----------(Elapsed Time: 01:13, VBatt start/end: 13.5V/13.5V)-----------

And.....

[ciclo]

Excellent! Good job, thank you very much for this report.
It's good to see that everything was meticulously inspected and that no more damaged wires were found. You had a good help for this task.

Now it is safe to drive your 6R.


I see a new address 5F in the autoscan , you must disable addresses 37 and 77 from Gateway installation list.
I guess your license plate lights are still under dimmer switch control...

When possible for you, there is no hurry. my email is waiting to receive your original ECU file.

[patil]

Excellent! Good job, thank you very much for this report.

My pleasure Master.

Now it is safe to drive your 6R.

Yes, Thank you.

I see a new address 5F in the autoscan , you must disable addresses 37 and 77 from Gateway installation list.

If I disable addressess 37 and 77, navigation and compass doesn't work. The gateway also throws error saying gateway module is improperly coded.

I guess your license plate lights are still under dimmer switch control...

Yes Master, I haven't done isolating plate lights from dimmer switch. I will do it shortly.

When possible for you, there is no hurry. my email is waiting to receive your original ECU file.

Sure, I will send you the ECU file soon.

[ciclo]

Many things to solve in your new 5F unit, I don't know the process, but 37 and 77 will end up being disabled.

New electrical installation for plate lights with BCM Max:
- Forget the installation that I proposed when BCM High was installed in your 6R.
- 6.5m of new 0.5mm2 wire from T73b/7 to power both license plate lights (near to plate lights). You must insulate the original cut wires (very important). It is explained in several installation guides that I made for 6R (IND), ... so the friends that were mentioned can also help you with this.

[patil]

Many things to solve in your new 5F unit, I don't know the process, but 37 and 77 will end up being disabled.

Spoke to seller regarding this issue, he insists on enabling both for proper functioning. I read on drive about this and didn't get any proper solution.

New electrical installation for plate lights with BCM Max:
- Forget the installation that I proposed when BCM High was installed in your 6R.
- 6.5m of new 0.5mm2 wire from T73b/7 to power both license plate lights (near to plate lights). You must insulate the original cut wires (very important). It is explained in several installation guides that I made for 6R (IND), ... so the friends that were mentioned can also help you with this.

Thanks a lot Master .... I will finish this wiring installation soon.

[patil]

Update regarding GRA High activation.

I am trying for past several days unsuccessfully to run the eobd2 application on win7. Once it opened but crashed immediately.

I followed the installation instructions carefully, but no success in running the application.

Master, any other way out to make it work?

[ciclo]

The antivirus and firewall must always be disabled (throughout the process), online OFF, from the moment you install the program until you finish reading the ECU file.
Try it with an old laptop.

On the other hand and as a last resort, there are new versions of Galletto and Kess V2 with which you would not have these problems.