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Thread: 3.0 TDI ZF8 Calibration pre-emissions "fix" restoration

  1. #1
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    3.0 TDI ZF8 Calibration pre-emissions "fix" restoration

    My Audi Q5 3.0 TDI was recently subjected to the much maligned emissions "fix" which among other things dramatically altered the transmission warmup and normal shift patters such that the engine wrecks itself with excessively high rpm's during cold start, refuses to respond without delay and needlessly holds higher gears during normal driving.

    Anticipating the damage I bought an mpvi2 and read the prefix transmission configuration to a hpt file which could be opened by the VCM suite. Reading the post fix configuration results in a VCM error because the newer OS is unsupported. I've submitted the newer hpt and vcm configuration logs as advised.

    A couple of questions I'd appreciate answers to:
    Is it possible to overwrite the current post-fix configuration by loading the pre-fix hpt file within the VCM stuite and then attempting a write via mpvi2 or does the OS revision have to match?
    If impossible I gather if and when the newer OS is supported, the older settings will need to be transferred somehow to the newer base configuration. Is there a direct migration strategy or procedure to upgrade an older OS configuration file to be compatible with the newer OS revision or does all the available configuration data need to be manually copied to the newer OS base configuration?

    Cheers

  2. #2
    We do not support a method of completely changing the OS back to the old one. That'd require an entire read of what is on the controller, and we only read the calibration data due to limitations in the controllers software.

    What you can do though is once the new operating system is defined is copy your old to your new. There's a couple ways to this, but the one I typically use is:
    1. Open your new file.
    2. Open your old file as a Compare file. (Compare > Open Compare File)
    3. Open the Comparison Log (Compare > Open Comparison Log)
    4. Right click on the highest member on the list, and "Copy Over All Differences".

    You could also go through each individual change made and see which of them you'd like to keep or not.
    There may be some changes still left in undefined tables that wouldnt be copied over, but most of whats left undefined in the ZF8 accounts for hardware differences, of which you will have zero as its the same transmission.
    If its not broke, just give it time.

  3. #3
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    Thanks for the quick response.
    The steps provided allowed me to copy the pre-fix differences, of which there are many, to the recently captured TCU configuration which I then flashed to the TCU. Following the flash, which occurred at a fraction of the read time, I re-read the TCU, saved the file and compared to the pre-fix template and all seemed consistent.
    The cold start behaviour, however, remains exactly the same with excessively high rpm's during engine warm up so either the necessary shift parameters were not captured, not written despite the tool indicating success or hidden elsewhere and not exposed.

    I've noticed the Shift Mapping for the warm up is grayed out and indicated shift pattern 30/31 which is no different from the pre emission "fix" configuration. The shift mapping mapping however which used to map shift patterns 30 - 30 and 31 - 31 now maps both 30 and 31 to shift pattern 5 and also cannot be altered. In desperation I attempted to copy the old shift pattern from 31 to 5 but following a flash, there is still no discernable difference in shifting behaviour.

    If anyone with experience reverting the Audi TDI emissions ZF8HP nonsense to a pre-fix state or an idea of why my current approach is failing could provide some guidance it would be much appreciated.

  4. #4
    Quote Originally Posted by sparcplug View Post
    Thanks for the quick response.
    The steps provided allowed me to copy the pre-fix differences, of which there are many, to the recently captured TCU configuration which I then flashed to the TCU. Following the flash, which occurred at a fraction of the read time, I re-read the TCU, saved the file and compared to the pre-fix template and all seemed consistent.
    The cold start behaviour, however, remains exactly the same with excessively high rpm's during engine warm up so either the necessary shift parameters were not captured, not written despite the tool indicating success or hidden elsewhere and not exposed.

    I've noticed the Shift Mapping for the warm up is grayed out and indicated shift pattern 30/31 which is no different from the pre emission "fix" configuration. The shift mapping mapping however which used to map shift patterns 30 - 30 and 31 - 31 now maps both 30 and 31 to shift pattern 5 and also cannot be altered. In desperation I attempted to copy the old shift pattern from 31 to 5 but following a flash, there is still no discernable difference in shifting behaviour.

    If anyone with experience reverting the Audi TDI emissions ZF8HP nonsense to a pre-fix state or an idea of why my current approach is failing could provide some guidance it would be much appreciated.
    Could you take a log with the Shift Source Base logged? The warmup mode is seldom used as is by most OEMs I've noticed, but that will indicate what "process" is controlling it.
    I wonder if the ECM itself is causing the shifts to hold out further (which is a possibility, the ECM and TCM coordinate on EVERYTHING), which that would show.


    Do you have a
    If its not broke, just give it time.

  5. #5
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    As a complete beginner, I've absolutely no idea how to log the shift source base. That being said the alterations did seem to take effect; perhaps I failed to notice the effects on the initial attempt. Applying the pre-fix differences to the post fix file and altering the map 5 which the warmup 30/31 patterns are mapped to causes all manner of problems and results in the torque converter failing to lock correctly issuing a transmission code; likely because I failed to overwrite map5's corresponding torque converter lockup settings pattern with map 30's.
    I've since reverted to the original post fix configuration to avoid any futher potential damage while I learn what exactly all the settings mean. The only change now is the reversion of the shift and torque converter mapping mappings back to the prefix state, not the value collections they reference; ie warmup settings 30/31 map to 30/31 rather than 5/5.

    My ultimate goal was merely to revert the warmup shifting cycle to a pre-fix state and the normal shift patterns aswell to allow much lower rpm shifting by default similar to the pre-fix state.
    The rpm values in the tables don't appear to match the actual shift rpm's at all if the rpm's are input shaft values. Anyway once I can identify the shift source I'll proceed accordingly.
    Are there any ZF8HP tcm alteration tutorials available?