[thecrave]

I'm trying to repair my 2016 eGolf. After attempting to run an output test (ENG1311-Cell-Controller_Numbering) in module 8C (the High Voltage Battery Management Controller -J840) using VCDS, I received a red triangle with bang, and error, "Error: Electrical system. Stop!" While the car powers on, it will not drive. In running this test, I was simply curious for more info. Prior to this, the vehicle was operating just fine. 

Seems the worst error is in that module 8C:

Code:

23264 - Internal Control Module

          P060C 00 [01100101] - Main Processor Performance

I hoped for a reset by letting it sit for 24 hours with both the HV and 12V disconnect as well as what I could find with VCDS to clear codes. 

Current situation - I took it to the dealer hoping they could do some sort of guided adaptation, etc., but no luck. They stated they have done remote diagnostics with VW techs using ODIS and they've proposed a repair to "Cell Circuit 'C'" which involves dropping the entire battery pack from the car, opening it and replacing three cells - one 5QE-915-599-AH and two 5QE-915-599-AK cells. To me, this doesn't make sense (see the scan below), as there are reported issues in more than just those units.

Parts and labor estimate is USD $9,000 due to all the modules being part of the high voltage battery assembly, almost as much as the car is worth!

I would have expected a reset or re-calibration of the HV system, particularly the J840 HV module (module 8C / 5QE 915 227) to be the correct next step, not a physical replacement of cells. To me, this is a software issue.

My thought is to get the car back and flash the J840 module (5QE 915 227) using ODIS-S (there is a TSB I can use SVM code - "3DA3"). I have logins from a repair shop. Else, I can use ODIS-E to try and flash a newer software to that module, but hoping that SVM process re-does adaptations.

Welcome any feedback on this approach and any other recommendations. If I can't get it to work, the car is done.

Here's a VCDS scan showing module 8C. There were no errors prior to running the output test.

Code:

Address 8C: HV Battery (J840)      Labels: 5QE-915-227.clb
  Part No SW: 5QE 915 227 M    HW: 5QE 915 227 H
  Component: K8C          H13 0722
  Coding: 000000000000000000000000000000000000000000000000000000000000
  Shop #: WSC 00000 000 00000
  ASAM Dataset: EV_BECM08820215QE915227M 003016
  ROD: EV_BECM08820215QE915227H.rod
  VCID: 52A06100052D66062D-XXXX

5 Faults Found:
23264 - Internal Control Module
          P060C 00 [01100101] - Main Processor Performance
          Not Confirmed - Tested Since Memory Clear
            Freeze Frame:
                    Fault Priority: 1
                    Fault Frequency: 1
                    Mileage: 38575 km
                    Date: 2024.11.01
                    Time: 15:54:54

                    Unlearning counter according OBD: 40
                    Current of H-V / hybrid battery: 0.000 A

18413 - Internal Temperature Measurement
          U1409 00 [00100100] - Implausible Signal
          Intermittent - Not Confirmed - Tested Since Memory Clear
            Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 1
                    Mileage: 38575 km
                    Date: 2024.11.01
                    Time: 15:58:40

                    Unlearning counter according OBD: 40
                    Current of H-V / hybrid battery: 0.000 A
                    Battery temperature: 14.234 °C

18376 - Battery Control Module 3
          U01A2 00 [00100111] - No Communications
          Not Confirmed - Tested Since Memory Clear
            Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 38575 km
                    Date: 2024.11.01
                    Time: 15:54:54

                    Unlearning counter according OBD: 40
                    Current of H-V / hybrid battery: 0.000 A

18386 - Battery Control Module 5
          U01A4 00 [00100111] - No Communications
          Not Confirmed - Tested Since Memory Clear
            Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 38575 km
                    Date: 2024.11.01
                    Time: 15:54:54

                    Unlearning counter according OBD: 40
                    Current of H-V / hybrid battery: 0.000 A

18394 - Battery Control Module 7
          U01A6 00 [00100111] - No Communications
          Not Confirmed - Tested Since Memory Clear
            Freeze Frame:
                    Fault Priority: 2
                    Fault Frequency: 2
                    Mileage: 38575 km
                    Date: 2024.11.01
                    Time: 15:54:54

                    Unlearning counter according OBD: 40
                    Current of H-V / hybrid battery: 0.000 A

[thecrave]

I tried flashing the module with ODIS-E and it failed about 35% through the process (2 minutes).

I've tried multiple other versions of the firmware with the same result.

It's not completely dead, as it is in a "Programmable" state but I'm just not able to get it to take an update. It stops after about 2 minutes and "returned a negative response" and aborts.

Any suggestions? The module is integrated with the high voltage battery, so I'm not able to simply swap it out.

[hestech]

I tried flashing the module with ODIS-E and it failed about 35% through the process (2 minutes).

I've tried multiple other versions of the firmware with the same result.

It's not completely dead, as it is in a "Programmable" state but I'm just not able to get it to take an update. It stops after about 2 minutes and "returned a negative response" and aborts.

Any suggestions? The module is integrated with the high voltage battery, so I'm not able to simply swap it out.

Try guided fault finding if possible.