2002 Jetta MK4 - AZG - help with emissions codes 16804, 17704 (scan included)

[cleland]

I finally received the dreaded notice from the Illinois State emissions test, for my 2002 Jetta. It has had a CEL for a while now, however it's been running great so I haven't really spent any energy trying to get it fixed. Of course it failed the test, so I have a couple months to get things fixed so I can renew the plates.

Here is the last Auto-Scan I collected, which shows the two codes in question -- any help diagnosing and repairing these is greatly appreciated.

Thanks!

=========================

Saturday,03,March,2012,13:44:19:23346
VCDS Version: Release 11.11.2
Data version: 20120126



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Chassis Type: 9M - VW Jetta IV
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
75 76

VIN: 3VWRB69M12M022483 Mileage: 169360km/105235miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 06A-906-032-AZG.clb
Part No: 06A 906 032 FP
Component: 2.0l R4/2V 4072
Coding: 00003
Shop #: WSC 00066
VCID: 71E3D7B03BB23BB
3VWRB69M12M022483 VWZ7Z0A3834624

2 Faults Found:
16804 - Catalyst System; Bank 1
P0420 - 35-00 - Efficiency Below Threshold
17704 - Error in Mapped Cooling System (check Temp-Sensor and Thermostat)
P1296 - 35-00 -
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 01M-927-733.lbl
Part No: 01M 927 733 KQ
Component: AG4 Getriebe 01M 4892
Coding: 00000
Shop #: WSC 00000
VCID: 89131F50B322E3B

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ABS.lbl
Part No: 1C0 907 379 C
Component: ABS FRONT MK60 0103
Coding: 0004097
Shop #: WSC 00048 551 00000
VCID: 2A5100DC86E4083

No fault code found.

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Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 F
Component: 04 AIRBAG VW6 0202 0004
Coding: 12340
Shop #: WSC 00066
VCID: 3A71309C2644B83

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

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Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 906 K
Component: KOMBI+WEGFAHRSP VDO V58
Coding: 07232
Shop #: WSC 02131
VCID: 306512B4F038723
3VWRB69M12M022483 VWZ7Z0A3834624

No fault code found.

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Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00066
VCID: F0E552B4B0B8B23

No fault code found.

-------------------------------------------------------------------------------
Address 35: Centr. Locks Labels: 1C0-962-258-III.lbl
Part No: 1C0 962 258 AC
Component: 21 Zentr.Verriegel. 0003
Coding: 00018
Shop #: WSC 00066
VCID: 68D5BAD40868FA3

2 Faults Found:
00928 - Locking Module for Central Locking; Front Driver Side (F220)
54-10 - Incorrectly Equipped - Intermittent
01044 - Control Module Incorrectly Coded
35-00 - -

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1J0-035-18x-56.lbl
Part No: 1J0 035 180 D
Component: RADIO 3CP 0002
Coding: 02401
Shop #: WSC 00066
VCID: 2045E2F4A0D8C23

No fault code found.

End ---------------------------------------------------------------------

[Jack@European Parts]

Do a warm up test of the cooling system and watch the ECT temps rise uniform.

Check ECT and T-Stat verify proper flow of pump or stuck open stat.

Check airmass and air cleaner before replacement of cat and verify amplitude in VCDS 01-04-046

[cleland]

Thanks for the quick reply -

could you explain what you mean by:

"verify amplitude in VCDS 01-04-046"

Thanks -

[Jack@European Parts]

In VCDS

01 engine electronics button then 04 basic settings button then channel/group 046 ON next GO

[cleland]

I reran a new auto-scan this evening, as well as several of the standalone tests. Here is the log, with the tests at the end:

======================


Wednesday,25,April,2012,20:25:36:23346
VCDS Version: Release 11.11.3
Data version: 20120401



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Chassis Type: 9M - VW Jetta IV
Scan: 01 02 03 08 09 15 16 17 19 22 29 35 36 37 39 46 47 55 56 57
75 76

VIN: 3VWRB69M12M022483 Mileage: 170930km/106210miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 06A-906-032-AZG.clb
Part No: 06A 906 032 FP
Component: 2.0l R4/2V 4072
Coding: 00003
Shop #: WSC 00066
VCID: 71E3D7B03BB23B1
3VWRB69M12M022483 VWZ7Z0A3834624

2 Faults Found:
16804 - Catalyst System; Bank 1
P0420 - 35-00 - Efficiency Below Threshold
17704 - Error in Mapped Cooling System (check Temp-Sensor and Thermostat)
P1296 - 35-10 - - Intermittent
Readiness: 0000 0000

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 01M-927-733.lbl
Part No: 01M 927 733 KQ
Component: AG4 Getriebe 01M 4892
Coding: 00000
Shop #: WSC 00000
VCID: 89131F50B322E31

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 1C0-907-37x-ABS.lbl
Part No: 1C0 907 379 C
Component: ABS FRONT MK60 0103
Coding: 0004097
Shop #: WSC 00048 551 00000
VCID: 2A5100DC86E4089

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 6Q0 909 605 F
Component: 04 AIRBAG VW6 0202 0004
Coding: 12340
Shop #: WSC 00066
VCID: 3A71309C2644B89

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

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 1J0-920-xx5-17.lbl
Part No: 1J0 920 906 K
Component: KOMBI+WEGFAHRSP VDO V58
Coding: 07232
Shop #: WSC 02131
VCID: 306512B4F038729
3VWRB69M12M022483 VWZ7Z0A3834624

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 00066
VCID: F0E552B4B0B8B29

No fault code found.

-------------------------------------------------------------------------------
Address 35: Centr. Locks Labels: 1C0-962-258-III.lbl
Part No: 1C0 962 258 AC
Component: 21 Zentr.Verriegel. 0003
Coding: 00018
Shop #: WSC 00066
VCID: 68D5BAD40868FA9

1 Fault Found:
00928 - Locking Module for Central Locking; Front Driver Side (F220)
54-10 - Incorrectly Equipped - Intermittent

-------------------------------------------------------------------------------
Address 56: Radio Labels: 1J0-035-18x-56.lbl
Part No: 1J0 035 180 D
Component: RADIO 3CP 0002
Coding: 02401
Shop #: WSC 00066
VCID: 2045E2F4A0D8C29

No fault code found.

End ---------------------------------------------------------------------
Wednesday,25,April,2012,20:35:35:23346
VCDS Version: Release 11.11.3
Data version: 20120401


Address 01: Engine (06A 906 032 FP)

20:35:14 Group 034: Lambda Control (Aging Check: Bank 1 Sensor 1)
760 /min Engine Speed (G28)
490.0°C Catalytic Converter Bank 1 Temp.
1.718 Dynamic Factor Bank 1 Sensor 1
B1-S1 OK Result Lambda Aging

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Address 01: Engine (06A 906 032 FP)

20:36:05 Group 036: Lambda Control (Sensor Readiness - After Catalyst)
0.755 V Sensor Voltage Bank 1 Sensor 2
B1-S2 OK Result Lambda Availability
Bin. Bits
Bin. Bits

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Address 01: Engine (06A 906 032 FP)

20:37:28 Group 046: Lambda Control (Catalytic Conversion Test Bank 1)
760 /min Engine Speed (G28)
525.0°C Catalytic Converter Bank 1 Temp.
0.50 Catalytic Conversion Bank 1
Cat B1 Not OK Cat. Conversion Test Bank 1

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Readiness Status: 0000 0000
Exhaust Gas Recirculation: Passed
Oxygen Sensor Heating: Passed
Oxygen Sensor(s): Passed
Air Conditioning: Passed
Seconday Air Injection: Passed
Evaporative Emissions: Passed
Catalyst Heating: Passed
Catalytic Converter(s): Passed

[Jack@European Parts]

Start with the ECT and make sure its green revised one not black.

Change T-stat to 92 degree C .

Try this.

http://cgi.ebay.com/ws/eBayISAPI.dll...e=STRK:MESE:IT

[cleland]

I'm going to do the ECT and the stat today, hopefully that will get me part of the way there.

[cleland]

ECT and thermostat replaced yesterday --

The job was easier than I thought in some respects, and much more difficult than I thought in others.

1) The ECT is trivial to remove/replace. My car already had the newer "green" sensor but I replaced it, the o-ring and the clip anyway. The old o-ring was cracked and looked pretty bad off.

2) The thermostat was another story. It didn't help that I started off wasting about an hour removing the wrong housing -- I initially removed the housing on the drivers side of the engine, where the ECT was, thinking it was the thermostat housing. Once I got it off, I quickly realized that it was not the right one. I got it back on but it was a b**ch to get the bottom stud threaded and in place.

After that debacle I quickly realized where the correct thermostat housing was, and spent quite a while scratching my head trying to figure out how to get the bottom bolt out. I looked at several threads which say "you don't have to remove the alternator". Finally, a trip to Sears for a 1/4" u-joint was the ticket. Once I used the socket to break it loose, I reached in with my fingertips to slowly unscrew the bolt about 1/8 turn at a time until it was out. The top bolt was relatively easy to get out. As I had already drained the radiator, very minimal coolant came out when I removed the stat. When putting the housing back on, putting the bottom bolt in was very difficult, again b/c of minimal clearance. I used my fingertips to get it started and at the very end was able to get the socket back on to snug it up.

Refilled the coolant, checked for leaks, good to go!

Today I ran VAG-COM again and cleared the codes, I'll see what happens in a day or two.

[cleland]

Just a quick followup -- I finally replaced the catalytic converter (manifold back) and the rear O2 sensor (the old one was frozen into the original pipe) -- after a couple drive cycles everything is clear, MIL is off and I passed the IL state emissions inspection!

Thanks to everyone for your help.

On to the next problem, I have developed a medium-slow coolant leak, I'm thinking it's probably the coolant flange, but might be the thermostat housing since I had them both off. I guess that's another afternoon project sometime when it's not too hot outside :-)

[Keithuk]

VAG Error Code: 16804
EOBD II Error Code: P0420

Fault Location:
Catalytic Converter System, Bank 1 - Efficiency Below Threshold

Possible Cause:
Leakage in Intake and/or Exhaust System.
Catalyst faulty.
Oxygen Sensor(s) faulty.
Oxygen Sensor(s) Control faulty.

Possible Solutions:
Check Intake and Exhaust System for Leaks.
Check Catalyst.
Check Oxygen Sensor(s).
Check Oxygen Sensor(s) Control.
Perform Oxygen Sensor(s) Aging Check.

Special Notes:
For 1.8T's experiencing this fault code, this thread may be useful: Aftermarket DP/Cat -DTC - Cat efficiency below threshold - Who has this DTC and wich DP/Cat

VAG Error Code: 17704
EOBD II Error Code: P1296

Fault Location:
Error in Mapped Cooling System

Possible Cause:
Cold start issues.

Coolant Temperature Sensor (G62) faulty.
Coolant Thermostat faulty.

Possible Solutions:
Check Coolant Temperature Sensor (G62).
Check Coolant Thermostat.

Special Notes:
Check the stored Freeze Frame data with this fault code. Freeze Frame information will be found in the fault code description (if the module supports it) or in Generic OBD-II if the vehicle complies with those regulations.
Freeze Frame data stored at -40*C is generally an indication of a faulty ECT or wiring.
Freeze Frame data stored at +140*C is generally an indication of a faulty ECT or wiring.
Freeze Frame data stored with in the 68*C ~ 80*C range is an indication that the vehicle was close to, but not within, the cooling systems normal operation range. The Thermostat itself or Cooling system components may be at fault.

VAG Error Code: 00532
EOBD II Error Code: P1750

Fault Location:
Supply Voltage B+ - Signal too Low

Possible Cause:
Wiring/Connectors from/to Control Module faulty.
Power Supply (Battery/Generator) faulty.

Possible Solutions:
Check/Repair Wiring/Connectors from/to Control Module.
Check Power Supply (Battery/Generator).

Special Notes:
When found in an individual control module, it's most likely a local source (e.g. wiring/connectors).
When found in multiple control modules at the same time, it's most likely a common source (e.g. earth spot, battery, generator).
Intermittent codes are often stored during low outside temperature when the battery capacity goes down and may be ignored.
Common with 16946/P0562/001378 - System Voltage: Too Low stored in other control modules.

VAG Error Code: 00928

Fault Location:
Locking Module for Central Locking; Front Drivers Side (F220) - Implausible Signal

Possible Cause:
Door Locks not working properly.

Wiring/Connectors from/to Locking Module for Central Locking; Front Driver Side (F220) faulty.
Voltage Supply for Locking Module for Central Locking; Front Driver Side (F220) faulty.
Door Lock Mechanics are stiff/partially seized.
Locking Module for Central Locking; Front Driver Side (F220) faulty.

Possible Solutions:
Check Wiring/Connectors from/to Locking Module for Central Locking; Front Driver Side (F220).
Check Voltage Supply for Locking Module for Central Locking; Front Driver Side (F220).
Check Door Lock Mechanics/Operation.
Check Locking Module for Central Locking; Front Driver Side (F220).

VAG Error Code: 01044

Fault Location:
Control Module - Incorrectly Coded

Possible Cause:
Reduced Functionality.

Control Module incorrectly coded.

Possible Solutions:
Check Gateway Installation List.
Check/Fix Control Module Coding.
See Vehicle Specific Diagnostic Procedures for Details.

Special Notes:
When found in CAN-Gateway,
On a Long Coded module, use the Gateway Installation List to check for unreachable or not registered control modules. Then update the Gateway [Installation List] by altering the Gateway Coding manually.
On a Short Coded modules, refresh the original coding with the same value. For example, code it from 00006 -to- 00006 without making an actual change.
When found in the Comfort System on the VW New Beetle/Cabriolet (1C/1Y/9C) this may be a bug in the module that will be resolved by refreshing the coding with the same value as described above with the CAN Gateway example.