- Joined
- Feb 25, 2014
- Messages
- 2,831
- Reaction score
- 4,569
- Location
- Garrettsville, OH
- 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.
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...
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.
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...
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:
