Category Archives: CAN bus

Volkswagen wire and cable specifications

An automotive wiring harness employs wires and cables. Each is made up of at least seven conductor strands (A), and
covered with an insulating material (B).

Within Volkswagen, wire and cable are classified in three general categories, and then specified according to size, type of insulation, and color.

 

 

 

 
Wires
Wires are stranded conductors ranging in size from 0.35 mm2 to 6.0 mm2 (approximately 22 to 9 gage (AWG)) that
make up most of a vehicle’s wiring harness. Smaller sizes save cost and weight. The larger sizes accommodate higher current loads with less resistance.

Wire larger than 6 mm2 (0 gage (AWG) is generally considered “cable.”

Wire size
Wire size (cross-sectional area) is the primary factor that will determine the current-carrying capacity of a conductor. Standard sizes differ slightly, depending on which measuring standard is used.

Volkswagen uses wire and cable that is manufactured according to the German industrial or “DIN” standards. Wire size is defined by cross-sectional area, and is measured in circular mils (mm2). As in the example shown, “0.75 mm” refers to the area (0.75 mm2), not the diameter.

Sizes of wire and cable originating in North America are described according to the American Wire Gage (AWG) standard. The standard wire sizes in both systems are roughly equivalent.

CAN bus gateway removing, installing and upgrading – Volkswagen Golf

The role of the Gateway (also known as the Data bus diagnostic interface J533) is the exchange of data between the CAN data bus systems (‘powertrain CAN data bus’, ‘convenience CAN data bus’ and ‘infotainment CAN data bus’) and the conversion of diagnostic data from CAN data bus systems to K-cable and vice versa so the data can be used by vehicle diagnosis, testing and information systems like the dealer VAS tools and Vagcom/VCDS.

For various reasons including power drain issues with third generation head units or the addition of new unsupported modules the CAN bus gateway must be upgraded to a newer revision. This guide covers the replacement of the CAN bus gateway in a 2005 MY06 Volkswagen Golf GTI. The upgrade replaces the 1K0 907 530 E (1K0907530E) with a 1K0 907 530 AA (1K0907530AA).

This process works the same for most Volkswagen models.

1K0 907 530 E (1K0907530E)
Revision: 11

1K0 907 530 AA (1K0907530AA)
Revision: H16

Record current installation list and long coding

Take screen shots or make a note of your installation list in controller 19 – Can Gateway using Vagcom/VCDS. This step is critical unless you want to figure out what you had installed prior to the upgrade. Don’t be tempted to copy down the long code unless you are installing the exact same revision of gateway as different revisions have extra features.

volkswagen_can_bus_gateway_upgrade_installation_list_before_01

Whilst not essential it is worth taking a screen shot of the different screens in the long coding.

volkswagen_can_bus_gateway_upgrade_long_coding_before_01 volkswagen_can_bus_gateway_upgrade_long_coding_before_02

Removing and Installing the Gateway

Remove the key from the ignition or disconnect the car’s battery (the battery disconnect is optional but better safe than sorry)

Remove the footwell cover on the drivers side where the gateway is located – Volkswagen Golf footwell cover drivers side – Removal and  Installation.

The gateway can be in two locations on the Golf. One is above the accelerator pedal and the other is above the clutch pedal (if fitted). The clutch pedal location was used for the first year or so of production.

MY05 gateway location

volkswagen_golf_can_bus_replacement_01 volkswagen_golf_can_bus_replacement_02

Removing

  • Release the connector and pull the connector off the data bus diagnostic interface.
  • Press three securing pins together and push out of holes to release or the holder is hinged and release that.

Installation

  • Install in the reverse order of removal.

Reconnect the battery

MY06 onwards gateway location

volkswagen_gateway_data_bus_diagnostics_removal_01

Removing

  • Release the connector (1) and pull the connector off the data bus diagnostic interface (2).
  • Press securing pins (3) together (see arrows) and push out of holes to release.

Installation

  • Install in the reverse order of removal.

Reconnect the battery

Coding the new gateway

Using the screen shots and notes from earlier you can now recode the gateway. Below are screenshots showing the differences between the two gateways (old gateway on the left and new gateway on the right

volkswagen_can_bus_gateway_upgrade_installation_list_before_02 volkswagen_can_bus_gateway_upgrade_installation_list_after_02

Volkswagen Central Electronics Control Module (CECM)

The Central Electronics Control Module (CECM) is situated above the pedals on the drivers side and controls all the lights in the car, monitors them, controls what appears in the MFD under the lights menu, controls the leaving home and coming home lights function,  controls the horn(s) and other features. There are different variants of this module called the Medium and the Highline, the latter is required for fog lights, bi-xenons and other features.

Partial listing of CECM’s and their details

3C0 937 049 (3C0937049) – 21 Byte – Medium
3C0 937 049 A (3C0937049A) – 21 Byte – Medium
3C0 937 049 B (3C0937049B) – 21 Byte – Medium
3C0 937 049 C (3C0937049C) – 21 Byte – Highend
3C0 937 049 D (3C0937049D) – 21 Byte – Medium
3C0 937 049 E (3C0937049E) – 21 Byte – Highend
3C0 937 049 F (3C0937049F) – 21 Byte – Medium
3C0 937 049 G (3C0937049G) – 21 Byte – Highend
3C0 937 049 H (3C0937049H) – 23 Byte – Medium
3C0 937 049 J (3C0937049J) – 23 Byte – Highend
3C0 937 049 K (3C0937049K) – 23 Byte – Medium
3C0 937 049 L (3C0937049L) – 23 Byte – Highend
3C0 937 049 P (3C0937049P) – 23 Byte – Medium
3C0 937 049 Q (3C0937049Q) – 23 Byte – Highend
3C0 937 049 R (3C0937049R) – 23 Byte – Medium
3C0 937 049 S (3C0937049S) – 23 Byte – Highend
3C0 937 049 T (3C0937049T) – 23 Byte – Medium
3C0 937 049 AA (3C0937049AA) – 23 Byte – Highend
3C0 937 049 AB (3C0937049AB) – 23 Byte – Medium
3C0 937 049 AC (3C0937049AC) – 23 Byte – Highend
3C0 937 049 AD (3C0937049AD) – 23 Byte – Medium
3C0 937 049 AE (3C0937049AE) – 23 Byte – Highend
3C0 937 049 AF (3C0937049AF) – 23 Byte – Medium
3C0 937 049 AG (3C0937049AG) – 23 Byte – Highend
3C0 937 049 AH (3C0937049AH) – 30 Byte – Medium
3C0 937 049 AJ (3C0937049AJ) – 30 Byte – Highend
3C0 937 049 AK (3C0937049AK) – 30 Byte – Medium
3C0 937 049 AL (3C0937049AL) – 30 Byte – Highend
3C8 937 049 A (3C8937049A) – 30 Byte – Medium
3C8 937 049 D (3C8937049D) – 30 Byte – Medium
3C8 937 049 E (3C8937049E) – 30 Byte – Highend
3C8 937 049 F (3C8937049F) – 30 Byte – Highend
3C8 937 049 G (3C8937049G) – 30 Byte – Medium
3C8 937 049 H (3C8937049H) – 30 Byte – unsure
3C8 937 049 N (3C8937049N) – 30 Byte – unsure
3C8 937 049 P (3C8937049P) – 30 Byte – unsure
3C8 937 049 Q (3C8937049Q) – 30 Byte – unsure
3C8 937 049 R (3C8937049R) – 30 Byte – Highend
3C8 937 049 S (3C8937049S) – 30 Byte – Highend
3C8 937 049 AA (3C8937049AA) – 30 Byte – unsure
3C8 937 049 AB (3C8937049AB) – 30 Byte – Highend

Build harness using connector housings and repair wires for Volkswagen Skoda Bluetooth Install

Whilst this guide is intended for the Volkswagen Skoda Bluetooth kit harness it applies to anything that requires interfacing to the quad lock connector on the rear of the head unit or that uses similar connectors around the car. This guide specifically for 2 x power connections and 2 x data connections.

The way this works is you remove the terminal from the housing, join that terminal to the matching terminal and insert the opposite terminal into the housing.

First you need to obtain the connector housings and repair wires.

  • 1 x 000 979 133 (000979133) – 1mm repair wire – CAN bus Hi and Lo female.
  • 1 x 000 979 134 (000979134) – 1mm repair wire – CAN bus Hi and Lo male.
  • 1 x 000 979 225 (000979225) – 2.5mm repair wire – 12v and ground female.
  • 1 x 000 979 226 (000979226) – 2.5mm repair wire – 12v and ground male.
  • 4 x 191 972 701 (191972701) – Housing
  • 4 x 191 972 711 (191972711) – Connector Housing
Alternatively you could replace the four housings and connector housings with a single housing and connector housing.
  • 1 x 1J0 972 704 (1J0972704)  – Housing
  • 1 x 191 972 714 (191972714) – Connector Housing

Step 1 – Cut the four repair wires in half, remove the insulation from the ends of all four and twist the exposed wire together. Do the same for the power and CAN bus wire. Join one male and one female repair wire half together (ensure that you join the 2.5mm female to the 2.5mm male) as shown and connect the ground wire to one and redo the step for the power wire.

vw_skoda_bluetooth_harness_connector_housing_1

Step 2 – Solder each of the four repair wire halves and the two power wires from the harness as shown.

vw_skoda_bluetooth_harness_connector_housing_2

Step 3 – Double the harness wire back on top of itself.

vw_skoda_bluetooth_harness_connector_housing_3

Step 4 – Using heat shrink cover each soldered area as shown. Use a smaller length to cover the join and than place a longer length over the top to minimise the chances of any shorts.

vw_skoda_bluetooth_harness_connector_housing_4

Step 5 – Repeat the last part of Step 1 with the 1mm repair wire and the CAN bus cable.

vw_skoda_bluetooth_harness_connector_housing_5

Step 6 – Place a piece of coloured heatshrink on one male/female CAN bus set, ensure that these are connected to the same wire! This allows you to ensure that you have hooked this up correctly later on. Repeat for the power set of cables.

vw_skoda_bluetooth_harness_connector_housing_6

Step 7 – This should be the finished result. Next tape it up using fabric adhesive tape – Fabric Adhesive Tape for wiring looms and harnesses

vw_skoda_bluetooth_harness_connector_housing_7

Step 8 – Install the housings and connector housings on the exposed terminals.

vw_skoda_bluetooth_harness_connector_housing_8

Step 9 – This is the finished harness ready for install.

vw_skoda_bluetooth_harness_connector_housing_9

Upgrading 2nd generation radios (RCD 300, RCD 500) to 3rd generation (RCD 210, RCD 310, RNS 310, RCD 510) power drain issue

VAG 1K0907530S CAN bus gateway
VAG 1K0907530S CAN bus gateway

Early build Volkswagen cars can experience a power drain issue after upgrading their 2nd generation headunit from a RCD 300 or RCD 500 to a 3rd generation headunit like the RCD 210, RCD 310, RNS 310 and RCD 510.

The problem is the CAN bus Gateway is too old and an updated version 1k0907530 (1k0 907 530) of L revision or higher is required – CAN bus gateway removing, installing and upgrading – Volkswagen Golf.

in vehicles belonging to the model series PQ35/PQ46 from
model year 2008 as well as the Tiguan,

Vehicles belonging to the model series PQ35/PQ46 from model year 2008 (MY08) as well as the Tiguan have gateways that are updated. Earlier models may require the updated CAN bus gateway to be installed. See Volkswagen Model Year Information for more details on the week of manufacture however generally Volkswagen change over Model Years around Week 22.

This problem does not* affect retrofits of the RNS 510 which is a 3rd generation head unit as this unit was in the production in 2007 whereas the RCD 210, RCD 310, RNS 310 and RCD 510 are recent additions.

Check the ‘Skoda Parts’ link (right hand menu) for a reasonably priced gateway. Revisions that will work after the 1K0 907 530 S (1K0907530S) revision include 1K0 907 530 AA (1K0907530AA), 1K0 907 530 AB (1K0907530AB) and 1K0 907 530 AC (1K0907530AC).

* This problem does now affect the RNS 510 if the firmware is upgraded to 2660 or higher. The RNS 510 will exhibit the same problems as the RCD 210, RCD 310, RNS 310 and RCD 510 and requires the CAN bus gateway to be upgraded.

Performing repairs on CAN bus wiring

canbus_repair_n97-0261An unshielded two-wire line (1) and (2) with a cross section of 0.35 mm² or 0.5 mm² is used for CAN bus wiring.

The colour codes of the CAN bus wiring are:

  • Powertrain CAN high wire Orange/black
  • Convenience CAN high wire Orange/green
  • Infotainment CAN high Orange/violet
  • CAN low wire, (all) Orange/brown

Repairs to CAN bus wiring can be carried out either with sections of repair wiring with the correct cross section or with entwined wires “green/yellow” or “white/yellow” available from VW spare parts.

When repairs are performed, both bus wires must have the same length. When the wires (1) and (2) are twisted, the length of each complete twist must be 20 mm (A).

There must not be any section of untwisted wiring longer than (B) = 50 mm, for example in the vicinity of welded joints as shown.

Mark the area of repair with yellow insulation tape to make it easy to identify.

000 979 987 (000979987)  – CAN cable (10M)

Fabric Adhesive Tape for wiring looms and harnesses

Volkswagen Cloth Webbing Adhesive Tape
Volkswagen Cloth Webbing Adhesive Tape