2000 Polo 6KV5 1.4 16v (APE) EML, Limp home mode, the works.

[doctordubs]

Got it tony. Ul get the mail at about 18.00 hours C.A.T

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[Tony S]

Before anything im going to cross check the codes on my autodata wich gives detailed description of code and reasons.

Nicholas,

Were you ever able to perform an "autodata code cross check" to see what it throws up?
If so, maybe you could kindly include it with tonights e-mail.

[Tony S]

Well, I've been able to borrow the VAG-COM again this evening and immediately tried the EGR and TB adaptation .......... Once again failed on both counts!!!
I really don't know what to do now.

[doctordubs]

Ignition ONEngine OFFSystem voltage at least 11.0 V.[Select][01 - Engine][Basic Settings - 04]Group 063[Go!]Activate the Basic Setting.[ON/OFF/Next]Press the pedal to the floor and hold it their for at least 2 seconds.Observe Field 4, once the adaptation is successfully done it should show "ADP. O.K.".[Done, Go Back][Close Controller, Go Back - 06]Switch Ignition OFF.

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[doctordubs]

Try this. I think ur trying to adapt what isn't there. Im under the impression ur pedal assembly controls the lot

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[Tony S]

Will do Nicholas, I've never tried block 63, so anything for a possible success.

Another thing I've come across, after doing a lot more research ........
I don't seem to have a 12v feed for either the TB or EGR. So I could have a broken wire, bad connector, or blown use .......... Somewhere!!!

As I've mentioned before, I've already checked all the engine bay wiring harness connectors and all the fuses by the driver's right knee 'cubby hole' fuse box.

By the way, I never did receive the wiring diagrams on either e-mail address, so I'm still working in the dark.


Tony

[Tony S]

Well, I must update this thread ...........

After a lot more investigations and discussions with my mate from Lotus Engineering, he suspected that the ignition switch contact assembly might be faulty.
He thought this, as I finally managed to get my hands on a wiring diagram for my car and checked all the circuitry to the TB and EGR valve. It transpired that the TB is fed via the ECU and the EGR is fed via fuse No. 30
The feed to fuse No. 30 was only reading 10.2v and the output from the ECU (to the TB) was 9.4 volts. So that's what made him think that the feed from the ignition switch was at fault.
So I ordered a brand new and genuine VW ignition switch contact assembly (from Poland at £16 inc P&P) ......... So that's us up to date.

The ignition switch contact assembly arrived yesterday but I haven't yet been able to fit it, as I'm not able to remove the steering wheel and column as a complete item, as the UJ is welded to the bottom of the steering column and won't pass through the column support tube. That would have allowed a minute amount of access to reach the screw that holds the contact assembly in place.
So, as I can't remove the steering column, I'm going to have go through the tedious process of removing the air bag, steering wheel, indicator and wiper stalk / switch assembly, splined collar and ignition switch, just to access the contact assembly ................ Unless someone knows of an easier method ??

Anyway, this evening, just to test my theory, I plugged the ignition contact assembly into the wiring loom and put the ignition key into the lock (just to pacify the immobiliser circuit) then used a screwdriver to turn the contact assembly switch ................... Bingo .............. It started perfectly, with no EML or limp home symptoms and it revved normally.

So, one second hand TB, one second hand EGR and a brand new EGR, ECU removal and PCB inspection, plus almost 8 weeks of head scratching later, the problem has been solved by a £16 ignition switch assembly!!!



But As mentioned, I still have to install the blessed thing, so any hints or tips would be gratefully appreciated.

[Tony S]

Well, I must update this thread ...........

The ignition switch contact assembly arrived but I haven't yet been able to fit it, as I'm not able to remove the steering wheel and column as a complete item, as the UJ is welded to the bottom of the steering column and won't pass through the column support tube. That would have allowed a minute amount of access to reach the screw that holds the contact assembly in place.
So, as I can't remove the steering column, I'm going to have go through the tedious process of removing the air bag, steering wheel, indicator and wiper stalk / switch assembly, splined collar and ignition switch, just to access the contact assembly ................ Unless someone knows of an easier method ??


Anyway, this evening, just to test my theory, I plugged the ignition contact assembly into the wiring loom and put the ignition key into the lock (just to pacify the immobiliser circuit) then used a screwdriver to turn the contact assembly switch ................... Bingo .............. It started perfectly, with no EML or limp home symptoms and it revved normally.


So, one second hand TB, one second hand EGR and a brand new EGR, ECU removal and PCB inspection, plus almost 8 weeks of head scratching later, the problem has been solved by a £16 ignition switch assembly!!!



But As mentioned, I still have to install the blessed thing, so any hints or tips would be gratefully appreciated.

[Tony S]

Now installed and working as it should.
Thanks to all who helped me with this marathon fault finding exercise.

[doctordubs]

Wow....il put this in my never forget bank lol. Gee wizz tony. In my 10 years iv never known a ignition switch to cause this much problems. Maximum respect to you and ur mate at lotus

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