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Thread: 2003 VW Beetle High Emissions

  1. #1
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    2003 VW Beetle High Emissions

    I've recently bought a Beetle (2.0 l AZJ) which was sold as spares or repair. The accelerator pedal was not working. I diagnosed that the post cat lambda sensor had shorted from the heater circuit to the sensor circuit and fried the ECU. I replaced the post cat lambda sensor, got the pin from the ECU with VAG Commander and replaced the ECU with one with the same part number. The car runs now.

    I took the car for its MOT and it failed on emissions, high CO. Lambda and HC were fine. Checked the cat and the insides rattled so I have just replaced that. The insides of it were all broken up and fell out through the pipe. I've just put it in for a retest so fingers crossed it will pass now.

    One thing I have noticed with it though is that the idle speed seems to be perfectly stable at 760 rpm apart from some small random peaks where it spikes to 800 rpm. There is also a slight hesitation/stumble at 1000 - 1200 rpm. There's no fault codes showing.

    I've checked the plugs and there's not one that looks any wetter or sootier than the others and the coil pack looks new. I've removed leads from spark plugs one at time and all give the same rpm response. One thing I noticed when I removed lead 3 from the coil pack was that it was arching back onto itself. I've done a visual check for vacuum leaks.

    Does anybody have any ideas what this could be?

    Full scan below.

    Code:
    Wednesday,21,December,2016,19:58:01:22812
    VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
    VCDS Version: 16.8.4.2 (x64)
    Data version: 20161129 DS267.0
    www.Ross-Tech.com
    
    
    VIN: WVWZZZ9CZ4M500876   License Plate: BEETLE1
    Mileage: 119470km-74235mi   Repair Order: 001
    
    
    Chassis Type: 9C (1C - VW New Beetle (1998 > 2010))
    Scan: 01 02 03 08 15 17 19 25 29 35 37 39 46 54 56 65 75
     
    VIN: WVWZZZ9CZ4M500876   Mileage: 119470km-74235miles
    -------------------------------------------------------------------------------
    Address 01: Engine        Labels: Redir Fail!
       Part No: 06A 906 032 GM
       Component: 2.0l 2V AGW         3943  
       Coding: 00001
       Shop #: WSC 00066  
       VCID: 6FEDCD292DC4103A20-515C
       WVWZZZ9CZ4M500876     VWZ5Z0C5188418
    
    No fault code found.
    Readiness: 0110 1001
    
    -------------------------------------------------------------------------------
    Address 03: ABS Brakes        Labels: 1C0-907-37x-ESP-F.lbl
       Part No: 1C0 907 379 M
       Component: ESP FRONT MK60      0102  
       Coding: 0019458
       Shop #: WSC 00066 000 00000
       VCID: 34670245546273E21D-5140
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
       Part No: 1C0 909 605 A
       Component: 47 AIRBAG VW51 03   0008  
       Coding: 13367
       Shop #: WSC 00066  
       VCID: 224BF41DAE96ED52FF-4B02
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 17: Instruments        Labels: 1C0-920-x4x.lbl
       Part No: 1C0 920 940 C
       Component: KOMBI+WEGFAHRS. M73 V04  
       Coding: 01412
       Shop #: WSC 00000  
       VCID: 1F4DFDE99DE4C0BAD0-4B1A
       WVWZZZ9CZ4M500876     VWZ5Z0C5188418
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
       Part No: 6N0 909 901 
       Component: Gateway K<->CAN    V042  
       Coding: 00006
       Shop #: WSC 00066  
       VCID: 70EFCE5530FA0FC239-4B02
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 46: Central Conv.        Labels: 1C0-959-799.lbl
       Part No: 1C0 959 799 F
       Component: 2Q Komfortgerát HLO 0004  
       Coding: 00064
       Shop #: WSC 00066  
       VCID: 3A7B2C7D26068592C7-4B02
    
       Subsystem 1 - Part No: 1C1959801A
       Component: 2Q Tőrsteuer.FS KLO 0010  
    
       Subsystem 2 - Part No: 1C1959802A
       Component: 2Q Tőrsteuer.BF KLO 0010  
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 56: Radio        Labels: 1J0-035-18x-56.lbl
       Part No: 1C0 035 186 
       Component:  Radio BNO         0006  
       Coding: 00003
       Shop #: WSC 00066  
       VCID: 5BB589F9C97C9C9AFC-4B02
    
    No fault code found.
    
    End-------------------------(Elapsed Time: 03:58)--------------------------

  2. #2
    NostraJackAss Jack@European_Parts's Avatar
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    Bad MAF.........TV not adapted, dirty or in error.
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  4. #3
    Ross-Tech Employee Jef's Avatar
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    Does unplugging the MAF cause the engine to run better?

    After an extended test drive, what are your Long Term Fuel Trim readings? 5 miles, then look at 01-08-032, what are the values?

    Have you done a sanity check of the MAF?

    Here's a good sanity check for the status of your MAF. Do a full-throttle run all the way to redline in a single gear (second works fine). Group 002 usually shows air mass in g/s (in many modern ECU's, consult your Factory Repair Manual for the specific group for your particular vehicle). Your peak airflow should be roughly 0.80 times your horsepower if you are close to sea level. So, if you have a stock 150 hp 1.8T, expect around 120 g/s. If you see significantly less than that, you MAF may be on the way out.
    Source:
    http://wiki.ross-tech.com/wiki/index.php/Fuel_Trim_Info

    Have you verified all 8 hamsters are still alive?
    Jef
    Ross Tech Support Team, Alpha Squad
    Auto-Scan, learn it, love it, live it... then check the fuses.

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  6. #4
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    So I've got the car back from the garage and its passed the emissions test. CO 0.04% HC 11 ppm Lambda 1.0.

    The misfire is till present though.
    Unplugging the MAF makes no difference to miss fire.
    I've changed the MAF and plug leads. I tried a new coil pack but this caused a serious misfire on cylinder 3 which brought on the CEL, so I replaced the old one.
    I've cleaned and re-adapted the throttle body.
    I've done the MAF test with the new one. At red line the air flow was 92 and the engine is meant to be 114 hp. (114 * 0.8 = 91.2).
    Short term, idle fuel trim bounces between -3 and 3.
    Long term fuel trim is around -3.

    How much would you expect engine speed at idle to vary by? It blips momentarily by 20- 40 rpm randomly. Am I being too fussy?

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  8. #5
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    how about spark plugs and wires.

  9. #6
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    So I thought I'd go back to basics on this one. Negative fuel trim shows rich misfire.

    Causes:

    Bad Compression
    High Fuel Pressure
    Bad Spark
    Sticky Fuel Injector

    Compressions 15.5 / 13.5 / 15.25 / 15.0 (Min 7.0 and imbalance of 3.0)
    Fuel pressure with vac 2.25 barg without vacuum 2.75 barg
    Replaced Plugs, Leads and Coil

    So, I'm guessing fuel injector or the ECU I put in is faulty???

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