VCDS Help 2003 Eurovan SAI Readiness and No Comms with Many Modules

[2003forme]

Hi everyone,

I went to get my 2003 Eurovan smogged, and it failed due to the Secondary Air not being ready. I ran it through multiple days of start up cycles, and haven't been able to get it to read as ready. So I went ahead and connected VCDS (which I haven't used in several years), updated the software and firmware, and tried to run the Auto Scan. The only information I get is for the engine. I'm a VCDS neophyte, so hopefully this is just user error.

I was trying to figure out what might be causing the issue with the secondary air, but not sure how to proceed since I'm not getting any information.

My ECU was modified 4 years ago to bypass the immobilizer, but I've run a smog test in the interim and not had a problem with the 2nd air readiness, so hopefully can get some advice on next steps here to get this running correctly.

I also noticed the 7th/8th digits of my vin don't match the model of my Eurovan in VCDS. the "70" maps to the earlier van model, not my 2003 model. But I tried to scan it with both settings and had no luck.

I need some help trying to isolate what would be causing the 2nd air to not come ready.

Thanks for you help in advance.

Log file:
------------------------

Saturday,25,June,2022,13:34:52:00895
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 22.3.1.4 (x64) HEX-V2 CB: 0.4615.4
Data version: 20220407 DS337.0
www.Ross-Tech.com


VIN: WV2NB47043H0XXXXX License Plate: WAY3GO



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 7D - VW Transporter/Multivan (1996 > 2004)
Scan: 01 02 03 08 15 17 18 19 22 25 35 37 56

-------------------------------------------------------------------------------
Address 01: Engine Labels: 022-906-032-AXK.lbl
Part No: 022 906 032 AF
Component: MOTRONIC ME7.1 G 0003
Coding: 00013
Shop #: WSC 03738
VCID: 4FFB8FBB7ECD1B83065-5184

No fault code found.
Readiness: 0000 1000

End----(Elapsed Time: 03:26, VBatt start/end: 12.4V/12.4V. VIgn 0.0V)------

 

[Uwe]

While it is quite strange that nothing except your Engine "talks", that seems to be the least of your worries for now.

If you let the vehicle sit overnight and then do a cold-start, does the Secondary Air Pump run?

What if you step though the Output Test sequence? I would expect the Secondary Air pump to be in that sequence somewhere. Does it run?

-Uwe-

 

[2003forme]

Thanks Uwe for the reply. The SAI isn't super loud on my Eurovan, so I *think* it is running, but unlike the vacuum cleaner like sound on my 1.8T Passat it is harder to tell. I tried to cycle through the Output Test sequence, but ran into trouble there as I can't choose a specific one. The first test was EVAP and it spun something up that wouldn't stop when I went the Secondary Air test, so I had to abort the tests. When I tried several times after that (after power cycling the ignition and restarting VCDS) it either told me "ERROR FUNCTION NOT AVAILABLE" or "OUTPUT TEST SEQUENCE COMPLETE" (

) I cold start it 0:32 into the video and you can hear the fast idle and what might be the pump, but I'm not positive.

I did check the fuse to make sure it was good, so I'll try the output tests again tonight and hope it work this time. Any other hints on going straight to the Secondary Air pump directly would be great. I'll pull the belly pan and try to see if I can physically verify the pump is running or put 12 power to the plug to try and activate it.

Thanks again as I stumble to try and get to first base in gathering some information!

 

[Uwe]

I tried to cycle through the Output Test sequence, but ran into trouble there as I can't choose a specific one.

Yep, old-school KW1281 ECUs only have Sequential output tests.

When I tried several times after that (after power cycling the ignition and restarting VCDS) it either told me "ERROR FUNCTION NOT AVAILABLE" or "OUTPUT TEST SEQUENCE COMPLETE"

The Sequential Output Test on 01-Engine typically contains things like fuel injectors, so after it has been run once, (no matter whether you actually got to the fuel injectors or not) you must start the engine for a bit before the ECU will allow you to start the sequence over again. This logic exists in the ECU to prevent an excessive amount of fuel from washing the oil off the cylinder walls or worse, hydro-locking the cylinders.

Ross-Tech: VCDS Tour - Output Tests

Step through the sequence. I'd be very surprised of the SAI pump isn't in there somewhere, but the sequence is determined by the ECU, not by VCDS...


-Uwe-

 

[2003forme]

Got it, thanks that's helpful. The SAI is the 2nd item on the list of tests, I just was afraid because the 1st test for EVAP started a high pitch whining that didn't stop when it went to the next test and I aborted the test. I'll re-do it tonight and post back. Thank you!

 

[Uwe]

the 1st test for EVAP started a high pitch whining that didn't stop when it went to the next test

That's mildly surprising. I would let the EVAP test run for a bit (as much as a full minute) to see if it stops on its own. Usually those tests have a 30-60 second time-out, but again, the ECU determines this.

-Uwe-

 

[2003forme]

Ok maybe that's what was happening, it was still running and I was too hasty. I have my marching orders for after work. Thanks!

 

[2003forme]

Ok so I let the test run, the evap ran for about a minute or so, and then stopped. Unfortunately, when I went to go to the next test, "ERROR FUNCTION NOT AVAILABLE" appeared again. Don't know if it is helpful to "see" it, but here's what happened:

I'm going to power cycle the van again and see if I can skip to the next test like I did yesterday and see if it will run once the whine from the EVAP stops. Sometimes you just aren't very lucky =(

 

[Uwe]

Damn, your ECU is sure being stubborn. I haven't played with output tests on one like that in a very long time, but I would have expected the first output in the sequence to stop when you moved on to the Next one, and I wouldn't have expected "Function Not Available" when the first one timed out.

There's a 2001 with a very similar ECU in our office parking lot. Hopefully, I will be able to try it on that one to see if it behaves the same.

-Uwe-

 

[2003forme]

Thank you so much for sticking with me on this, I am not usually so *lucky* to have trouble at every turn =)

I did just get some timeout errors, init failed and kline no response. I swapped to a new USB port and will go plug the laptop in to make sure it has enough power. Not sure if these screenshots provide a clue?

https://imgur.com/a/9xWnn92

https://imgur.com/tGf98vh

UPDATE: Didn't make a difference, ran the engine again, re-tried the tests and just get the EVAP one and then the error. Stupid ECU =(

 

[2003forme]

Ok I was able to verify the SA pump is running on cold start, removed the hose didn't find any water, so the pump seems ok.

So not being able to run the output tests, is there any other method of tracing down why the 2nd air sensor won't come ready? So far I have done:

• verified the SAI fuse is good
• visually inspected the vacuum lines
• verified the pump comes on

So next I should check that the combi valve and vacuum lines aren't clogged which might cause it not to be ready even though the pump is running? Thanks in advance.

 

[Uwe]

Didn't make a difference, ran the engine again, re-tried the tests and just get the EVAP one and then the error. Stupid ECU =(

There is definitely something not right with your van. Andy and I just tested this stuff on the Ross-Tech "company truck". It's a 2001, but 2001-2003 are for all intents and purposes the same. Here's an Auto-Scan:

Wednesday,29,June,2022,17:26:39:25460
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 22.3.1.4 (x64)  HEX-V2 CB: 0.4615.4
Data version: 20220407 DS337.0
www.Ross-Tech.com


VIN: WV2KB47001H120059   License Plate: EUROVAN
Mileage: 104110km-64690mi   Repair Order: 22.3.1.4



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 70 (7D - VW Transporter/Multivan (1996 > 2004))
Scan: 01 02 03 08 15 17 18 19 22 25 35 37 56
 
VIN: WV2KB47001H120059   Mileage: 104110km-64690miles
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 022-906-032-AXK.lbl
   Part No: 022 906 032 F
   Component:  MOTRONIC ME7.1 G   0004  
   Coding: 00013
   Shop #: WSC 02743  
   VCID: 0E46A4537941523B4D3-51A8

No fault code found.
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 02: Auto Trans        Labels: 01P-927-733.lbl
   Part No: 01P 927 733 CE
   Component: AG4 Getriebe 01P    4841  
   Coding: 00000
   Shop #: WSC 00000  
   VCID: 78AAE28B6BC57C8BF7F-0962

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: None
   Part No: 7D0 907 040 
   Component: CLIMATRONIC         0003  
   Coding: 00032
   Shop #: WSC 02743  
   VCID: 5F98A917EE2BABB3965-2596

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 1J0-909-60x-VW3.lbl
   Part No: 1J0 909 603 BM
   Component: AIRBAG VW3 -        V04  
   Coding: 16973
   Shop #: WSC 02743  
   VCID: 75B4EBBF7CD701E3EC9-4B5C

1 Fault Found:
00532 - Supply Voltage B+ 
            07-10 - Signal too Low - Intermittent

-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 7D0-920-xxx-17.lbl
   Part No: 7D0 920 905 A
   Component: T4-KOMBIINSTR. VDO V09   
   Coding: 03235
   Shop #: WSC 02743  
   VCID: 2514FBFF8CF731639C9-513C

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels: 6N0-909-901-19.clb
   Part No: 6N0 909 901 
   Component: Gateway K<->CAN    0001  
   Coding: 00003
   Shop #: WSC 02743  
   VCID: 70BADAAB03B524CB3FF-513C

No fault code found.

-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 6X0-953-257.lbl
   Part No: 6X0 953 257 
   Component: IMMO                0008  
   Coding: 00001
   Shop #: WSC 00066  
   VCID: 7DA4F39F44E759A3A49-4B1E
   WV2KB47001H120059     VWZ1Z0A1230888

No fault code found.

-------------------------------------------------------------------------------
Address 35: Centr. Locks        Labels: 7D0-959-800.lbl
   Part No: 7D0 959 800 C
   Component:    Funksteuergerát  0001  
   Coding: 00001
   Shop #: WSC 02743  
   VCID: 2D0403DFD4070923549-4B1E

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 1J0-035-18x-56.clb
   Part No: 1J0 035 180 B
   Component:  Radio DE2         0005  
   Coding: 09400
   Shop #: WSC 02743  
   VCID: 1E66D413A9A1E2BBDD3-51F2

No fault code found.

End----(Elapsed Time: 02:14, VBatt start/end: 12.6V/12.5V. VIgn 0.1V)------

We also ran Output Tests on the engine. Andy took video, which I'll post once he has it uploaded. We used the same 22.3.1.4 version of VCDS you're using, with a HEX-V2, so a setup functionally identical to yours.

Observation: There is some kind of noise that starts during the first item in the sequence and continues even when stepping to subsequent items, but the subsequent items all make their own noises. Whether this will be apparent over the traffic noise we were dealing with right behind us is questionable though.

My first suggestion: Disconnect the aftermarket head unit you have installed in your van to see if you can then talk to other things besides just 01-Engine. The stock radio harness has a K-Line (the single-wire diagnostic bus) coming to it. If that's connected to anything at all on your aftermarket head unit, it can wreak havoc with diagnostic communications.

-Uwe-

 

[Uwe]

So next I should check that the combi valve and vacuum lines aren't clogged which might cause it not to be ready even though the pump is running?

Yeah, I think that sounds like a plan.

-Uwe-

 

[Uwe]

And here's the video:

You'll probably want to watch that bigger (full-screen?), but it clearly stepped though the entire sequence.

-Uwe-

 

[Dana]

Right and that noise at the beginning of the sequence, that continues the entire time, is likely the in-tank electric fuel pump. Most vehicles from this era used the fuel pump relay to power the pump -and-all of the solenoids so it had to run continuously in order to operate the individual components.

 

[2003forme]

Uwe, you're amazing, thank you for taking the video and checking. Something is definitely unhappy.

Awesome, Dana, I am pretty sure that's the sound I'm hearing. Ok I will disconnect the radio and give it a try, but I think the last time I did VCDS in 2018 (when I had a failed immobilizer) I was able to query all the rest of the systems like you did Uwe.

I want to just revisit the first post to make sure there's not something about the immobilizer bypass that is causing issues. Jack had disabled the immobilizer on my ECU, and then I had to run a line to ECU for the kline. I don't recall if I ever ran VCDS after that time, and I'm wondering if this bypasses all of the rest of the systems and simply does the 01 at the engine.

The damn combi valve is real bear to try and get at. The bottom 5mm bolt is blocked by the exhaust manifold cover so I'm still trying to figure out how to test that. I think I can try and unplug the vacuum line and apply a pump to it, but all these lines are brittle at the ends so I'm worried about creating more problems in the meantime

Here's my immobilizer thread you helped me with back in 2018.

New VCDS User: 2003 Eurovan can't communicate with ECM

Hi everyone, I have 2003 Eurovan that is a camping vehicle for us. We went out to start it, and it fires up, then dies 1 second later. Reading up, this seemed like it was an immobilizer problem, so I went ahead and got a new battery, shorted the battery terminals, left the key in the ON...

forums.ross-tech.com

You have to complete a repair to the K line, whether with bypass or overlay to the DLC using the WD and so VCDS or the State inspection facilities can query the 0x01 controller.

 

[Uwe]

I had to run a line to ECU for the kline. I don't recall if I ever ran VCDS after that time, and I'm wondering if this bypasses all of the rest of the systems and simply does the 01 at the engine.

No, bridging the K and W wires at the Immo should not affect communications with the rest of the systems in the van.

-Uwe-

 

[2003forme]

Ok back to square 0! I was able to run the output tests successfully after disconnecting the radio. No other controllers but now I need to figure out if they worked. The pump works (as I confirmed on startup) but I can't tell if anything is happening at all with the relay.

Here's a 2 minute run. I giggled happily at finally getting it to work so just ignore that part

 

[Uwe]

I was able to run the output tests successfully after disconnecting the radio.

That sounds like progress.

No other controllers

Pick a module, any module that you know should "talk". Check your wiring diagram to see where the K-Line should go on that module and do a continuity test between there and pin 7 of the diagnostic socket.

Or trace the wire from pin 7 of the diagnostic socket. It should go to some kind of "star" connection not too far into the dashboard. See what's going on there...

-Uwe-