Case Study: P0411 Secondary Air Injection System, Incorrect Flow Detected

   #1  

jyoung8607

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VCDS Serial number
C?ID=25607
2007 Volkswagen Rabbit with the 2.5L inline 5. Customer (youngest son) states MIL illuminated with no other drivability problem. Reviewed with VCDS and found a SAI problem that wasn't there as of a few days ago. The low voltage problems are unrelated; they trace back to me leaving the headlights on a few weeks ago, and I've replaced the battery since then.

Code:
Wednesday,16,December,2020,19:14:55:50497
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 20.12.0.1 (x64)  HEX-NET CB: 0.4535.4
Data version: 20201125 DS322.1
www.Ross-Tech.com


VIN: WVWBR71K47W034361   License Plate:


Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 15 16 17 19 25 42 44 46 52 56

VIN: WVWBR71K47W034361   Mileage: 190410km-118315miles

00-Steering Angle Sensor -- Status: OK 0000
01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: Malfunction 0010
19-CAN Gateway -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
56-Radio -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 06A-906-032-BGP.lbl
   Part No SW: 07K 906 032 S    HW: 07K 906 032 Q
   Component: 2.5l R5/4V      G   9032
   Revision: --H01---    Serial number: VWZ7Z0F7020288
   Coding: 0000003
   Shop #: WSC 01279 785 00200
   VCID: 392446ADD555C6D374C-806C

1 Fault Found:
001041 - Secondary Air Injection System
               P0411 - 002 - Incorrect Flow Detected - MIL ON
             Freeze Frame:
                    Fault Status: 11100010
                    Fault Priority: 0
                    Fault Frequency: 2
                    Reset counter: 255
                    Mileage: 189741 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 00:09:07

             Freeze Frame:
                    RPM: 1512 /min
                    Load: 46.6 %
                    Speed: 0.0 km/h
                    Temperature: 30.0°C
                    Temperature: 18.0°C
                    Absolute Pres.: 970.0 mbar
                    Voltage: 14.351 V

Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 09G-927-750.clb
   Part No SW: 09G 927 750 FL    HW: 09G 927 750 FL
   Component: AQ 250 6F           0920
   Revision: 00H38000    Serial number:           
   Coding: 0000072
   Shop #: WSC 01279 785 00200
   VCID: 0052EB49F60F571B732-8054

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels: 1K0-907-379-MK60-F.lbl
   Part No SW: 1K0 907 379 AC    HW: 1K0 907 379 AC
   Component: ESP FRONT MK60      0101
   Revision: 00H11001
   Coding: 0021122
   Shop #: WSC 01279 785 00200
   VCID: 73B8B485B7B97C837E0-8026

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 1K0-820-047.lbl
   Part No: 1K0 820 047 FP
   Component: Climatic PQ35   120 0606
   Shop #: WSC 00000 000 00000
   VCID: 77A08095A3C110A3428-8022

1 Fault Found:
00532 - Supply Voltage B+
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels:. 3C0-937-049-23-M.lbl
   Part No SW: 3C0 937 049 P    HW: 3C0 937 049 P
   Component: Bordnetz-SG     H46 1501
   Revision: 00H46000    Serial number: 00000005832251
   Coding: 008D0F214004150000140000001400000008730B5C0000
   Shop #: WSC 03103 444 54051
   VCID: 363E4D91E44B29AB99E-8062

   Subsystem 1 - Part No: 1K1 955 119 E  Labels: 1KX-955-119.CLB
   Component: Wischer 190606 020  0501
   Coding: 00038805
   Shop #: WSC 03103

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1K0-909-605.lbl
   Part No SW: 1K0 909 605 AB    HW: 1K0 909 605 AB
   Component: 5L AIRBAG VW8R  034 8000
   Revision: 05034000    Serial number: 003B6D051DV/
   Coding: 0013644
   Shop #: WSC 01269 785 00200
   VCID: 6C8AAFF9EA87A37BBFA-8038

   Subsystem 1 - Part No: 1K0 959 339 D
   Component: BF-Gewichtsens. 006 0006

   Subsystem 2 - Serial number: 6332MSME1075005D2

   Subsystem 3 - Serial number: 6342MSME10702713-

   Subsystem 4 - Serial number: 6352QSME0F284173H

   Subsystem 5 - Serial number: 6362QSME100F28116

   Subsystem 6 - Serial number: 63727SME0A380C2C7

   Subsystem 7 - Serial number: 63827SME0A3E46424

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 1K0-953-549-MY8.lbl
   Part No SW: 1K0 953 549 AL    HW: 1K0 953 549 AL
   Component: J0527           057 0070
   Coding: 0010022
   Shop #: WSC 19783 002 1048576
   VCID: 7CAA9FB99AE733FB2FA-8028

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 1K0-920-xxx-17.lbl
   Part No SW: 1K0 920 953 H    HW: 1K0 920 953 H
   Component: KOMBIINSTRUMENT VDD 1610
   Revision: V0003000    Serial number: VWZ7Z0F7020288
   Coding: 0007203
   Shop #: WSC 03103 444 84151
   VCID: 30327B89062F079BC32-8064

2 Faults Found:
00446 - Function Limitation due to Under-Voltage
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 129
                    Mileage: 190131 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 03:37:53

00532 - Supply Voltage B+
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 129
                    Mileage: 190131 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 03:37:53


-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels:. 1K0-907-530-V2.clb
   Part No SW: 1K0 907 530 H    HW: 1K0 907 951
   Component: J533__Gateway   H12 0150
   Revision:   H12       Serial number: 310010662205D7
   Coding: 3F0F034007000000
   Shop #: WSC 01279 785 00200
   VCID: 2C0A6FF92A07637BFFA-8078

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 1K0-920-xxx-25.clb
   Part No SW: 1K0 920 953 H    HW: 1K0 920 953 H
   Component: IMMO            VDD 1610
   Revision: V0003000    Serial number: VWZ7Z0F7020288
   Shop #: WSC 00000 000 00000
   VCID: 30327B89062F079BC32-8064

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels:. 1K0-959-701-MIN3.clb
   Part No SW: 1K0 959 701 M    HW: 1K0 959 701 M
   Component: Tuer-SG         005 0967
   Coding: 0001077
   Shop #: WSC 01279 785 00200
   VCID: 382243A9EE5FDFDB8B2-806C

2 Faults Found:
01811 - Supply Voltage for Door Controller; Drivers Side (J386)
            002 - Lower Limit Exceeded - Intermittent
00100 - Drivers Interior Locking Button (E308)
            008 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-144-G2V3.clb
   Part No: 1K1 909 144 L
   Component: EPS_ZFLS Kl.069 H07 1806
   Shop #: WSC 19783 002 1048576
   VCID: 343A7799F2373BBBA7A-8060

1 Fault Found:
00003 - Control Module
            005 - No or Incorrect Basic Setting / Adaptation - Intermittent

-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 1K0-959-433-MIN.clb
   Part No: 1K0 959 433 AF
   Component:    KSG              0401
   Coding: 13C803281B09058F880A048050CC
   Shop #: WSC 01287 785 00200
   VCID: 74BAB799B2B77BBB67A-8020

   Subsystem 1 - Component:   Sounder n.mounted 

   Subsystem 2 - Component:       NGS n.mounted 

   Subsystem 3 - Component:      IRUE n.mounted 

1 Fault Found:
00668 - Supply Voltage Terminal 30
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels:. 1K0-959-702-MIN3.clb
   Part No SW: 1K0 959 702 M    HW: 1K0 959 702 M
   Component: Tuer-SG         005 0967
   Coding: 0001076
   Shop #: WSC 01279 785 00200
   VCID: 392446ADD555C6D374C-806C

1 Fault Found:
01812 - Supply Voltage for Door Controller; Pass. Side (J387)
            002 - Lower Limit Exceeded - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1K0-035-161.lbl
   Part No SW: 1K0 035 161 B    HW: 1K0 035 161 B
   Component: Radio DE2       014 0016
   Revision: 00014000    Serial number: VWZ4Z7F6141622
   Coding: 0040401
   Shop #: WSC 01279 785 00200
   VCID: 1E6EB5316CBB81EB61E-804A

No fault code found.

End----(Elapsed Time: 00:59, VBatt start/end: 12.1V/12.3V. VIgn 12.0V)-----

The first thing I tried was stepping through the sequential output tests in 01-Engine. Got appropriate clicky sounds from the SAI combi solenoid. Also got clicky sounds from the SAI pump relay, but no hair-dryer sound of the pump spinning up, so that tells me it's a problem with the pump or its power supply and not the combi valve or a leak/measurement problem.

Checked fuses SB23 and SB27 in the under-hood fusebox and verified good. Removed the SAI relay and verified +12V at its input. Installed a jumper wire between the SAI relay A2 in/out contacts, still no response from the SAI pump. Lifted the car, and applied some light percussive maintenance directly to the SAI pump in case there was some internal stiction I could potentially clear, no result. Pulled the electrical connector off the SAI pump, and verified I had +12V at the harness connector with the A2 relay still jumpered.

At this point I was about to condemn the SAI pump, but when I plugged it back in, the pump spun up briefly. I was able to get intermittent response from wiggling around the connector. Upon looking closer...

pa2ypJi.jpg


Lots of contact corrosion. I'm not sure how this happened, the seals on the connector housing seemed like they were intact, although I didn't dig super deep. I didn't see any sign of something dripping onto it from above, or anything like that. Some light scraping/sanding of the terminals, followed by CRC electronics cleaner, followed by a healthy dab of Permatex dielectric grease to each terminal for a little protection against future moisture ingress, and the SAI pump is back in business. Output test of SAI pump relay spins up the pump as expected. Readiness code successfully generated in-garage using the factory End of Line procedure.

Vehicle returned to customer. No complementary wash due to customer being a punk who hasn't been turning in his schoolwork on time lately. Dad Extended Warranty billed for 1.5 hours of diagnostic and repair time including trip to Autozone for the dielectric grease and other misc shop supplies.
 
Last edited:
   #2  

NZDubNurd

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Vehicle returned to customer. No complementary wash due to customer being a punk who hasn't been turning in his schoolwork on time lately. Dad Extended Warranty billed for 1.5 hours of diagnostic and repair time including trip to Autozone for the dielectric grease and other misc shop supplies.

^ Classic :D
 
   #4  

Jef

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As per rule #8 of rule #4 of this section of the RT Forums:

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