Golf IV / Jetta IV :: 2005 TDI - ABS Engaging During Slow Speed Braking


Aug 6, 2016

Mk4 2005 TDI 190,00 KM

Background: Purchased this car couple months ago. Did a bunch of maintenance, including rear pads/rotors, fronts still good. Also decide to bleed the system while I had the car on jacks. Followed Bentley procedure as I have previously, using a pressure bleeder making sure to stay at 12 psi and kept the reservoir topped up at all times. First I did the clutch slave, brakes and last I did VAG com procedure to bleed the ABS unit. Upon completion pedal felt good and I took it for drive ..

Brakes worked fine under normal braking force but when the car was slowing down and coasting to a stop with my foot on the brake (light pressure) the ABS engaged briefly(speed around 10-15km /h) right before the car came to a stop. Assumed maybe air in the system so re-bleed the ABS pump again .. Nothing same ABS kicks in right before stopping .. Cleaned all speed sensors and rings .. Nothing, still happening.

Recap:

-ABS does not engage under regular braking force, brakes work fine.
-ABS engages under light braking pressure right before complete stop. (ie parking car or pulling into a drive way)

So my question is, is it possible an ABS sensor out of the 4 is causing this? How about the brake switch? I know that on older VWs used to be 2 pin but this one is 4. Is it possible there is ABS pump problem? Air still in the system? Master cylinder?

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I recently had my wheel hub and bearing replaced. The mechanic said I might hear a little noise with the brakes but they'd work. Turns out that noise is the Anti-lock braking system engaging every time I use the brakes. It happens when the car speed gets low, maybe 5-15 mph. Also, if I'm driving slow in a parking lot or something, and let off the gas, that change in speed sets the ABS system on too, without my foot being on the brake pedal.

I've also noticed sometimes when the weather is very cold, the ABS light will go on and the ABS brakes won't work; just regular brakes. Is this something that I'd be able to solve at home? Could I possibly bleed the brake lines to check for any air ( although braking seems fine ) , busted fuse for the system, anything else to check before asking the mechanic?

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For the past 4/5 weeks my truck vibrates when i brake at slow speed ex. Driving out of a parking spot, slightly braking no matter if i go forward, reverse, turn or go straight it'll vibrate, sometimes very lightly, but usually it's very noticeable, can be compared to the clutch pack issue with these trucks. I had the clutchpacks in the rear diff. replaced at 160k ,after that it drove very smooth but that only lasted 20/30k.

So when turning it'll vibrate at about 15/20 km/h, but that's because of them crappy clutch packs

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4x4
xtr package
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1. Without a lift can I check this under the hood instead of at the wheel? Possibly at the plug into the ABS module.
2. Someone else on another thread mentioned that their dealership hooked in a monitor and drove around.

When I asked my dealership how they would diagnose this, they said they would do the same check as I mentioned above (#1). This would be expensive and since it is intermittent, they might not see anything. Do this monitor exists and what it is called?

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Here's the story: was on my way downtown last night to get a new suit (I'm in Savannah, GA so it's hot) and AC was working great. The Jetta (2003 AWP) is a stock-everything-1.8T that has never had any AC work done to it from the day I bought it new. I figured it was doing just fine so just leave it alone. Anyway, leave the suit shop (bought a gray three-piece) and go back to the parking lot, start up and get ready to leave, no cold air from the vents. I get it home and do some reading on here and also in the Bentley manual and get into some preliminary troubleshooting. Here's what I have so far:

- Engine running/AC button ON/Blower on "3"/Recirculation OFF/Engine at operating temperature
- Turn blower ON - visually verified that clutch is not engaged and compressor is not spinning
- Shut car off, compressor does turn by hand easily
- With AC button on and blower on, passenger side cooling fan (behind radiator) is ON but driver side cooling fan IS NOT on - I think this indicates a problem from what I've read
- Checked cabin fuses 5, 16, & 25. All have low resistance (good continuity) and are not discolored. Just to make sure I scuffed the contacts with a scotchbrite pad and reinstalled them
- Same deal for the top-of-the-battery power distribution block. All fuses checked okay and were scuffed and reinstalled
- Moved on to the pressure switch/pressure sensor. My vehicle has the 3-pin sensor so jumping contacts is not a possibility. I need to rent/buy a duty cycle meter to check it. Any good tutorial on how to do this? Do I disconnect the connector and check it right at the switch or must I break out the wires and check it in parallel with the connector attached to the sensor?
- I grabbed a flat-head screwdriver and gave the high-pressure and low-pressure service valves a poke and got a good blast of pressure from them so I don't think the system is empty.
- Did a little more reading and found I needed to check voltage at the 3-pin connector on top of the battery power distribution block. I did this with the key ON - no power at any of the pins. Repeated with key ON and engine running with AC button ON and blower ON - still no voltage. For these measurements, the connector was DISCONNECTED. Does this matter? Do I need to have it plugged in to get voltage there (i.e., read the voltage from the rear of the connector with it installed?)
- Finally, and perhaps most enlightening, I suspected I may simply be low on R134a so I bought a can with a pressure gauge on it. Connected it to low-pressure side with engine running, AC button ON, blower on "4", recirculation OFF. The gauge read ~150 PSIG. Yes, this seems high to me too; however, the compressor is still not turning at this point. Does it need to turn to get a good pressure reading from the LP service valve? I recall from everything I read that if pressure is too low, the clutch won't engage, and if pressure is too high, the clutch won't engage

So, as far as I can tell I have a few problems...

1. The driver side fan doesn't run when AC button is ON
2. No voltage at the 3-pin connector on the battery power distribution block Incorrect methods...there is voltage there.
3. Low-pressure side of the AC system is too high Called and checked with a local mechanic...I won't receive correct pressures if the compressor is not turning.

My next steps are to check the voltage at the compressor connector for 12VDC. I suspect I'll get 0V because it's clearly not turning. I'll do this once I can figure out how to get the dang connectors apart without breaking them. 11-year-old heat fatigued plastic is brittle...

Finally got the compressor connector apart.. there is 12VDC on pin 1 and 0VDC on pin 2 (it's a ground, so there shouldn't be..ground continuity check good). Ohmed out the clutch...from what I can tell, that circuit is open. However, I am not 100% sure I was on the contacts because of how the connector is positioned. I'm going to get a dummy connector from a salvage yard and connect it up and make sure I have good contact before I call it a bad clutch.

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Got a weird issue that I've never encountered before. I tried searching but you can't search for just "A/C", so the search was pretty generic and I couldn't find anything similar to my issue.

Hot or cold, doesn't matter. When I turn the A/C on the clutch try's to engage and slowly starts to spin with the pulley until until it finally engages then the a/c will blow out cold air just fine. Also noticed a burning smell coming from it.

01 Jetta 2.0

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Where this has occurred is a rather odd exit off of I-70 to Wadsworth Blvd., you are exiting at pretty good speed from the Interstate, curving to the right, then to the left and pretty much braking the entire time, and going into a slight bank. You can feel the increase in G's as you make this exit. I have also driven the exit and greatly reduced my speed and level of braking and the issue with the ABS does not occur. My local dealer is at a loss to find or explain what is occurring.

My questions are, is there something seriously wrong with my braking system (ABS), if there is, what is it, if there isn't, why does it do this only under the conditions that it is occurring?

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I also scanned the truck and saw the code for a bad IWE solenoid so that is being replaced tonight. I also have not checked the drivers side yet.

So...now that I have done all of that, the truck started occasionally bucking/shuddering when I slow down from highway speed to about 30mph and lightly accelerate again. It does not do it every time though. There is no grinding/whining noises either. Could this be caused by the IWE system somehow? Maybe slowing losing vacuum and having one engage and the other disengaged?

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Ok here is the issue, my girlfriend owns a MK4 '99 Jetta. Through the search I was able to figure out why she is having so many issues with her door locks and how they can be fixed on the cheap..thats awesome. But here is the problem. She was driving down the road the other day, A/C working...then suddenly it stopped blowing cold. Fan is still working, just blows hot air. She said it started blowing warm suddenly and hasnt been getting warmer through out the past days or anything.

With the hood popped and the a/c on, you can see that the compressor isnt engaging. The car makes a noise like its engaging the compressor, but nothing is happening that I can see visually. Seems as if the compressor is not getting the signal to engage. It sounds like its trying to make the compressor kick on about every 5 seconds or so. Basically that initial clicking sound that your hear RIGHT before the compressor comes on when its working normally.

We have checked the fuses and no luck with those, all look good. Seems like its an electrical issue to me. What this may be? Bad pressure switch? Low pressure in the system? I know the car has had the compressor replaced before...and the clutch seems to spin freely when the car is off.

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Simultaneously I had a code for P0420/P0411 (the SAI incorrect flow crap which causes catalyst inefficiency) so I went ahead and swapped out the cracked SAI plastic hose leading to stock airbox, after doing so I reset the CEL and ran the car. And it ran like crap, I think it was in limp mode (i had never experienced this in my Jetta) from what Ive read, but not sure. So, I pulled to the side, and restarted car, let it sit, same problem. Finally, after 3-4 cycles it threw a CEL, which ironically FIXED the problem. It ran fine from then on. Made it home, hooked up scanner and CEL code was P0732, which I read elsewhere is a 'Gear 2 - Incorrect Ratio' meaning 2nd gear is messed up somehow.

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