Auto headlight retrofit. VW Transporter. T5 (2010-2015)

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reido80
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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by reido80 » Fri Jul 31, 2020 6:23 pm

Fuse box A in ebox
New feed for +30 6mm wire fused 30amp
IMG_0566.JPEG
Ran up original loom and fed through this grommet
IMG_0581.JPEG
Fuse box SB
IMG_0607.JPEG
Fuse box SC
IMG_0544.JPEG
Kufatec loom for ALWR that will be modified to pick up left headlight at T10/T14 and shortened in places. (i think it is specific to left hand drive).
IMG_0587.JPEG
ALWR unit (wrong one I think)
IMG_0592.JPEG
Also have a kufatec loom for rain & light sensors but I think it is wrong but can be made to work.

Also discovered I might have bought the wrong rear view mirror or I am missing another bracket from the windscreen. (Van has no back window in tailgate). I removed the cap from the existing mirror bracket on the windscreen but it seems something is amiss.
IMG_0597.JPEG
IMG_0600.JPEG

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ciclo
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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by ciclo » Sat Aug 01, 2020 2:52 am

Hi reido80.

Let's go with it ...

First thank for all the images and the two Autoscan posted.👌

ID:
Transporter T5. 'D' Model Year (05/2012 - 05/2013)

Wiring diagrams to be used:
-Headlights with halogen bulbs (H4) , (7L3/8K0/8K1/5D0/5D1/5D9) From May 2012 (Chapter 183)
-Headlight with gas discharge light , (8EC),(8ED),(8EM),(8EN) From May 2012 (Chapter 146)

https://drive.google.com/file/d/1z_-f0C ... sp=sharing (download if you need it)

---
For the wiring from the BCM connectors to the bixenon headlights take into account what was discussed here:
viewtopic.php?f=56&t=70736&start=30#p528541

---
Because you want to update the auto dimming mirror, I imagine you want to install the auto lights in addition to the bixenon headlights.
My recommendation is that you follow the scheme for H4 for the manufacture of the wiring:
viewtopic.php?f=56&t=70736&start=45#p528663

Automatic lights means having the rain light sensor installed, which is installed in conjunction with the automatic dimming mirror.

There are two ways to install the new auto dimming mirror (+RLS):
- Or you can change the windshield with the appropriate retaining plate for the new mirror.
- Or you install the retaining plate on your current windshield.

Image
e.g. :arrow: https://www.ecstuning.com/b-genuine-vol ... aa845543b/

There are many tutorials on the internet in the various forums dedicated to the VW group.


---
For the BCM adaptation and the rest of the lights, follow what is indicated here:
viewtopic.php?f=56&t=70736&start=45#p528735


---
The first thing you should do right now is this:
Image

This is where the BCM adaptation/replacement begins in order to be able to access the information of all the units with the VCDS.
- http://wiki.ross-tech.com/wiki/index.ph ... eplacement
You must matching the remote controls at this time, follow these ross-tech instructions scrupulously.
- http://wiki.ross-tech.com/wiki/index.ph ... ctory_Mode (value = 0)
- http://wiki.ross-tech.com/wiki/index.ph ... l_Clearing
- http://wiki.ross-tech.com/wiki/index.ph ... l_Matching

You do the process for the first remote control, entering the value 0, and then you do the same process for the second remote control, also entering the value 0, and so on with all the remote controls you have.

Once done, make a new autoscan, regardless of the units you have currently uninstalled.

You can now get rid of BCM 087 if it is your wish. :wink:

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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by ciclo » Sat Aug 01, 2020 4:17 am

There are more things to comment, because your new BCM Max (second hand) comes from a vehicle with Start/Stop (7L6), and your T5 is without Start/Stop (7L3), but we will solve this later.

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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by reido80 » Sat Aug 01, 2020 1:08 pm

Many thanks for your help Ciclo, I see now what you mean about the mirror.
I think when it comes to the auto lights, I will just run all the wiring ready to plug in at a later date. Would this be possible? I might change the windscreen for a heated T6 screen with correct sensors at a later date but that's another story.. :D



Ok, so this is where we are at-

Can lines between cluster and bcm-Done Had fun making the twisted wires :D

Keys coded

BCM codes copied from old.

Still have loads of errors, which is understandable, Passenger airbag fault is because the dash warning light is disconnected.


Code: Select all

Saturday,01,August,2020,12:48:19:03258
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 20.4.2.0 (x64)  HEX-V2 CB: 0.4513.4
Data version: 20200730 DS317.0
www.Ross-Tech.com


VIN: WV2ZZZ7HZDH021778   License Plate: 090BCM TEST2
Mileage: 130870km-81318mi   Repair Order: 



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


Chassis Type: 7H-VN75 (6N0)
Scan: 01 03 04 08 09 10 15 17 18 19 22 25 69 0B

VIN: WV2ZZZ7HZDH021778   Mileage: 130870km-81318miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
10-Park/Steer Assist -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
17-Instruments -- Status: Malfunction 0010
18-Aux. Heat -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
22-AWD -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
61-Battery Regul. -- Status: Malfunction 0010
69-Trailer -- Status: Cannot be reached 1100
-------------------------------------------------------------------------------
Address 01: Engine (J623-CFCA)       Labels:. 03L-906-022-CFC.clb
   Part No SW: 03L 906 019 GK    HW: 03L 907 309 L
   Component: R4 2,0L EDC   H37 3566  
   Revision: 22H37---    Serial number: 00000000000000
   Coding: 0119401A233600080000
   Shop #: WSC 02756 790 50316
   ASAM Dataset: EV_ECM20BTD01103L906019GK 003003
   ROD: EV_ECM20BTD01103L906019GK_003.rod
   VCID: 7AADF0A04C5F927B1C7-802E

3 Faults Found:
5568 - Sensor for Ambient Air Temperature (G17) 
          P0073 00 [039] - Signal too High
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:09

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 16 °C
                    Intake air temperature: 18 °C
                    Ambient air pressure: 990 mbar
                    Voltage terminal 30: 11.960 V
                    Unlearning counter according OBD: 40
                    Exh.gas temp.sen 1: 20.0 °C
                    Exh.gas temp.sen 2: -0.0 °C
                    Exh.gas temp.sen 3: 20.0 °C
                    Exh.gas temp.sen 4: 20.0 °C
                    Shut-off timer: last engine shut-off time: 3383 s

10065 - Mass Air Flow Sensor (G70) 
          P0104 00 [167] - Intermittent
          MIL ON - Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:08

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 16 °C
                    Intake air temperature: 18 °C
                    Ambient air pressure: 990 mbar
                    Voltage terminal 30: 11.960 V
                    Unlearning counter according OBD: 40
                    Air mass: actual value (mg/stroke): 0.0 mg/stroke
                    Standardized airflow ratio: filtered: 3.9999
                    EGR Solen.val.: actual value: 99.89 %
                    Throttle valve adapter: actual value: 104.42 %
                    Charge air pressure specified value: 1020 hPa
                    Charge air pressure: actual value: 994.4 hPa
                    Mean injection quantity: 0.00 mg/stroke

9531 - Manifold / Barometric Pressure Sensor (G71) / (F96) 
          P0105 00 [039] - Malfunction
          Not Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:08

                    Engine speed: 0.00 /min
                    Normed load value: 0.0 %
                    Vehicle speed: 0 km/h
                    Coolant temperature: 16 °C
                    Intake air temperature: 18 °C
                    Ambient air pressure: 990 mbar
                    Voltage terminal 30: 11.960 V
                    Unlearning counter according OBD: 40
                    Charge air pressure: actual value: 990.2 hPa
                    Intake air pressure sensor after air cleaner: raw value: 1150 hPa
                    Sensor for charge pressure between turbochargers: raw value: 994.2 hPa
                    Engine status: COENG_READY
                    Engine status-Test_Program_Co Eng st COMPU VERB UBYTE: 1

Readiness: 0 0 0 0 1 

-------------------------------------------------------------------------------
Address 03: ABS Brakes (-----)       Labels: 7E0-907-37x-MK25AXT.clb
   Part No SW: 7E0 907 379 J    HW: 7E0 907 379 E
   Component: ESP MK25A XT  H43 0109  
   Revision: 00H43001    
   Coding: 108764AD19A6089626A99878AA6610
   Shop #: WSC 02756 790 49152
   VCID: 392F2FAC0959596355D-806C

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J301)       Labels:| 7E5-907-047.clb
   Part No SW: 7E5 907 047 BG    HW: 7E5 907 047 BG
   Component: Climatic-T5   H20 0505  
   Revision: 00001010    
   Coding: 0000000002
   Shop #: WSC 02756 790 50316
   ASAM Dataset: EV_ClimaticT5 A01003
   ROD: EV_ClimaT5Basis.rod
   VCID: 75B7E39C6541FD03715-8020

1 Fault Found:
13701968 - Function Restriction due to Faults in Other Modules 
          U1113 00 [009] - -
          [Steuergerät im Schalttafeleinsatz - bitte Fehlerspeicher auslesen]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:06


-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 7H0-937-08x-09.clb
   Part No SW: 7H0 937 090 D    HW: 7H0 937 090 
   Component: BCM PQ25 Max4 H74 0725  
   Revision: B9074001    Serial number: 0671 186141457
   Coding: B8B079B80E61241192284E106E6985550080430F60844040320000000000
   Shop #: WSC 02739 790 12345
   VCID: 2F3B11F4C71D87D3FB9-807A

   Subsystem 1 - Part No SW: 7E0 959 801 C    HW: 7E0 959 801 C  Labels: 7E0-959-80X-V1.CLB
   Component: J386__TSG_FT  003 3313 
   Serial number: --------------------
   Coding: 050000

   Subsystem 2 - Part No SW: 7E0 959 802 C    HW: 7E0 959 802 C  Labels: 7E0-959-80X-V1.CLB
   Component: J387__TSG_BT  003 3313 
   Serial number: --------------------
   Coding: 050000

   Subsystem 3 - Part No: 7E1 951 172 
   Component: DWA-Sensor 00  001 0104 
   Coding: 000000

   Subsystem 4 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H05 1501 
   Coding: 000000

   Subsystem 5 - Part No: 7E1 951 172 
   Component: DWA-Sensor 00  001 0104 
   Coding: 000000

   Subsystem 6 - Part No SW: 5K0 959 542 A    HW: 5K0 959 542 A
   Component: E221__MFL-TAS  H09 0013 
   Serial number: 0390005             
   Coding: 820000

3 Faults Found:
03591 - Control Circuit for Horn 
            011 - Open Circuit
             Freeze Frame:
                    Fault Status: 01101011
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Time Indication: 0
                    Date: 2014.12.23
                    Time: 00:56:07

01516 - Terminal 30; Left 
            011 - Open Circuit
             Freeze Frame:
                    Fault Status: 01101011
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Time Indication: 0
                    Date: 2014.12.23
                    Time: 00:56:06

00927 - Terminal 30 (Right) 
            011 - Open Circuit
             Freeze Frame:
                    Fault Status: 01101011
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Time Indication: 0
                    Date: 2014.12.23
                    Time: 00:56:06


-------------------------------------------------------------------------------
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: 28261217200384
   Coding: 118001
   Shop #: WSC 02756 790 50316
   ASAM Dataset: EV_VW75XParkAssis8K 001003
   ROD: EV_VW75XParkAssis8K_001_VN75.rod
   VCID: 392F2FAC09D9596355D-806C

1 Fault Found:
13632256 - Function Restricted due to Missing Message(s) 
          U1111 00 [009] - -
          [Steuergerät für Anhängererkennung-J345 - kein Signal/keine Kommunikation]
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 6
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:06


-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 5K0-959-655.clb
   Part No SW: 7E0 959 655 B    HW: 7E0 959 655 B
   Component: VW10Airbag009 H07 0013  
   Revision: --------    Serial number: 003HL00CRH9K
   Coding: 000000000000000000000000000000003039
   Shop #: WSC 02754 790 50316
   ASAM Dataset: EV_AirbaVW10BPAVN750 A01026
   ROD: EV_AirbaVW10BPAVN750.rod
   VCID: 3537239C25C1BD03B15-8060

1 Fault Found:
9442836 - Front Passenger's Airbag Disabled Indicator Lamp 
          B1016 14 [137] - Open or Short to Ground
          MIL ON - Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:08


-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:| 5K0-920-xxx-17.clb-SRI1
   Part No SW: 7E0 920 970 G    HW: 7E0 920 970 G
   Component: KOMBI         H06 0605  
   Serial number: 00000000000000
   Coding: 160E00
   Shop #: WSC 02756 790 50316
   ASAM Dataset: EV_Kombi_UDS_VDD_RM09 A04716
   ROD: EV_Kombi_UDS_VDD_RM09_004_VW32.rod
   VCID: 2E050CF0C0978EDBF0F-807A

1 Fault Found:
9453330 - Outside temperature sensor 
          B103F 1B [009] - Resistance Too High
          Confirmed - Tested Since Memory Clear
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Date: 2020.08.01
                    Time: 00:56:06


-------------------------------------------------------------------------------
Address 18: Aux. Heat        Labels: None
   Part No: 7E0 815 071 B
   Component: J737__Standheizung  0605  
   Revision: 00085000    Serial number: 09019275F00000
   Coding: 0000031
   Shop #: WSC 02757 790 00000
   VCID: 2411EED892DB348B16B-8070

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 6N0-909-901-6R.clb
   Part No SW: 6N0 909 901     HW: 7H0 937 090 
   Component: GW-K-CAN TP20 H74 0725  
   Revision: B9074001    
   Coding: 042300
   Shop #: WSC 02739 790 12345
   VCID: 70B9D2881AA3D82BA23-8024

1 Fault Found:
01517 - Control Module for Trailer/Towing Sensor (J345) 
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 232
                    Mileage: 130877 km
                    Time Indication: 0
                    Date: 2014.12.23
                    Time: 00:56:11


-------------------------------------------------------------------------------
Address 22: AWD        Labels: 0AY-907-554-V1.clb
   Part No SW: 09N 907 554 B    HW: 09N 907 554 B
   Component: Haldex 4Motion      6008  
   Coding: 0000007
   Shop #: WSC 02756 790 00000
   VCID: 372B2994334D4F13A39-8062

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          H06 0605  
   Serial number:               
   Coding: 000000
   Shop #: WSC 12345 123 12345
   ASAM Dataset: EV_Immo_UDS_VDD_RM09 A03709
   ROD: EV_Immo_UDS_VDD_RM09_VW31.rod
   VCID: 6A8DC0E03CFF22FBEC7-803E

No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer
Cannot be reached

End----------(Elapsed Time: 02:04, VBatt start/end: 12.1V/12.1V)-----------
Last edited by reido80 on Sat Aug 01, 2020 2:40 pm, edited 1 time in total.

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ciclo
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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by ciclo » Sat Aug 01, 2020 8:58 pm

Perfect, everything has changed noticeably even if it doesn't seem like it.
Logically there are many faults due to having some parts/units uninstalled.
These faults will disappear as what is uninstalled is installed.
New faults will also appear when a new BCM coding is done (this will be fixed later).

---

The donor car's BCM 090D had a Bluemotion system, which means it had a Battery Monitoring Control Module (61).

Image

Module 61 can be removed from the installation list with the following procedure:

1- Go to Gateway 19, installation list, enable 61 (again).
2- Go to Battery monitoring 61 (now enabled), codify to 000000.
3- Come back to Gateway 19, installation list, disable 61.
4- Go to autoscan, click on GW installation list (not on Start), wait the result, clear all DTCs, wait the result ...
Module 61 must have disappeared from the installation list.
5- Check with a new Autoscan (Start button).

---
reido80 wrote:
Sat Aug 01, 2020 1:08 pm
Many thanks for your help Ciclo, I see now what you mean about the mirror.
I think when it comes to the auto lights, I will just run all the wiring ready to plug in at a later date. Would this be possible? I might change the windscreen for a heated T6 screen with correct sensors at a later date but that's another story.. :D
It is possible, but it is to duplicate the work on the connectors, especially on the T17 light switch connector. Better to get rid of this T17 connector now.

I recommend that you install the mirror and rain light sensor now, along with wiring for auto lights.
This is what is proposed in the diagrams for a T5 with xenon headlights.

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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by reido80 » Mon Aug 03, 2020 2:33 am

Hi folks, hope you have had a good weekend.

Many thanks for the above information and guidance, I will get more bcm coding done once it is safe enough to reconnect the battery. I will order the correct windscreen mount and mirror parts and get all the parts ready for a proper install.

Today's progress, one step forward two steps back kind of day!

Discovered that the laser tools pin extractor is rubbish! I spent a good part of the day messing about with them. The tool pins are just too soft and thin they just wont push the release pins down enough. I cant even remove fuse terminals (I slid the purple cage to the side as much as it would go) so I am on the lookout for a new set of tools.

Cut off the T17 switch plug,

Fitted 10 pin connector to the original T17 wiring. (if I have to remove this I will be in trouble as I tried to take a pin out but the tool just wont work).

Started to make the loom for auto lights and after many hours of fiddling and had crimped the JPT's to the wires I found that I have the wrong plugs/pins for the coupling. Completely my fault and will set me back waiting on more parts. We live and learn...
What i have is vw 10 pin connector 191972725 which is currently fitted with original t17 terminals clicked in. 191972735 is the end that takes the male terminals which I thought should be male JPT 2.8 but I cant get them to click in to this. It looks like it is meant for some other terminal type. Must be similar to JPT but with the pin offset slightly.

If I could ask a question to do with the loom please...

What terminals are needed for the relay holder?

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ciclo
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Re: Auto headlight retrofit. VW Transporter. T5 (2010-2015)

Post by ciclo » Mon Aug 03, 2020 5:38 am

This tool usually works well for many.
https://www.ebay.co.uk/sch/i.html?_from ... ol&_sop=15
I have had one for over 7 years and it works perfectly.
In all technical manuals related to removing terminals, it is commented that some experience is needed to remove the terminals. Patience. :)


Surprisingly, the four tools in the center of the image below are extremely useful for many jobs with small connectors and terminals. Search Aliexpress.
Image


For 191972735
Image

For 8E0937527 or 7M0937632B
Image

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