1996 VR6 Passat Emissions Code

[JCrane]

I recently tried to take my Passat to get it to pass emissions. The check engine light has been on for a while, but I was told by a mechanic in a neighboring county that what was causing the problem wasn't worth fixing. Well, I have moved to a county that has emissions testing, and it cannot pass till this is fixed.

Trouble code is P4011 Sec. AIR System Incorrect Flow Detected.

I took it to a VW dealer, and their diagnosis was that it needs a new combi valve and vacuum lines replaced (due to disintegration) all for the low price of $629! Does this sound right? I don't mind spending the money as long as it truly fixes the problem. Please help!

Jason

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[billsjrauto]

Maybe there is a temporary way around the immediate problem. So you can get inspected and then look around for a second opinion or a cheaper price.

My '97 has the same problem. My mechanic (local experienced mechanic - not dealer) believes that he can get the car to pass the emissions test even though the secondary air fault usually comes back illuminating the check engine light. He discovered if he clears all the faults in memory and allows the car to run, eventually all the tests (computer initiated) will be completed relatively quickly (hours). He also noticed that the secondary air fault only sets when the car is started. He plans to clear the code, let the engine run, drive it around some all while keeping his OBDII scanner attached. Once all the tests are completed and pass he will then perform the I/M test.

He has yet to do this because as he was attempting this procedure the clutch pedal failed allowing the master cylinder rod to push through the petal's rod holder resulting in the clutch always remaining engaged. So he need to fix this first.

I replaced three of the four vacuum hoses on the secondary air system. The original hoses disintigrated as on your car. There is one that will require removing that combi valve (just to replace the hose) - ultra poor design - thanks VW. Just a note - if the vacuum lines fail the vacuum can not get to the valve to open it. So may be the valve is OK.

Wish you the best!