VW Caddy 2K 1.9 Tdi BJB - Lack Of Boost After Engine Repair ...

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You are using an out of date browser. It may not display this or other websites correctly.You should upgrade or use an alternative browser. VW Caddy 2K 1.9 Tdi BJB - Lack of boost after engine repair ( snapped cam belt)

• Thread starter Thread starter LocomotiveR1
• Start date Start date Dec 12, 2021

Status Not open for further replies. Dec 12, 2021 #1

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Hi The woes started with a cam belt snapping. Damaged the cylinder head , valves and injectors. Fitted a used but good cylinder head and used injectors. As the vehicle was out of service I had the turbo serviced and tested. After assembling the motor it starts fine but smokes (black diesel smoke) more than it did before the belt broke. There is also no power at all with there being no boost ( as logged on the VCDS whilst driving). The turbo piping is airtight, the control vacuum is good and varies when controlled via VCDS ( measured with a vacuum gauge and pump). The air pressure sensors ( boost measurement and control) have been changed as with the MAF sensor. I now need to do the injector adaption as being different units to what was previously fitted, the value's will need to be adjusted I am sure. My problem is the "security code" for the adaption. The two I tried 27971 and 79153 both got me locked out ...... :-) . I bought a VW workshop manual, but was unable to locate this code I need, that's my first question, what code do I use, or where could I locate it? Checked the FAQ and various VW forums... no luck. I need to measure the lift pump in the fuel tank and the pressure line that feeds the PD injectors pressure from the vane pump on the cam. The fuel pressure gauge I have reads 0 -> 10 Bar, would this be sufficient to measure these line's? My thought is , low pressure to the injectors would cause them to have low output pressure ( I had the used injectors serviced/tested before fitting so I doubt they the issue). Not enough diesel = no power ? Any help/comments would be appreciated. Having enough 2T and 4T petrol engine experience, with diesel I'm an appy. I can supply a log (*.csv) of a drive I took but an unsure how to attach the file. Any other information that would help I can supply Kind regards Andre Code: copy Sunday,12,December,2021,10:46:00:03100 VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64 VCDS Version: 21.9.0.2 (x64) HEX-V2 CB: 0.4555.4 Data version: 20210903 DS330.0 www.Ross-Tech.com Dealer/Shop Name: Andre Venter VIN: WV1ZZZ2KZ7X041867 License Plate: ANDRE3 Mileage: 283690km-176276mi Repair Order: andre3 Chassis Type: 2K (1K0) Scan: 01 03 08 09 15 16 17 19 25 44 56 VIN: WV1ZZZ2KZ7X041867 Mileage: 283690km-176276miles 00-Steering Angle Sensor -- Status: OK 0000 01-Engine -- Status: OK 0000 03-ABS Brakes -- Status: Malfunction 0010 08-Auto HVAC -- Status: OK 0000 09-Cent. Elect. -- Status: Malfunction 0010 15-Airbags -- Status: OK 0000 16-Steering wheel -- Status: OK 0000 17-Instruments -- Status: OK 0000 19-CAN Gateway -- Status: OK 0000 25-Immobilizer -- Status: OK 0000 44-Steering Assist -- Status: OK 0000 56-Radio -- Status: Malfunction 0010 ------------------------------------------------------------------------------- Address 01: Engine Labels: 03G-906-016-BKC.clb Part No SW: 03G 906 016 DM HW: 028 101 188 2 Component: R4 1,9L EDC 0000SG 6045 Revision: 12345678 Serial number: VWZ7Z0F7101535 Coding: 0050071 Shop #: WSC 35110 377 00159 VCID: 71BE2BF4EDA9DB4358F-8024 VINID: 9E606AAAA09BA87A001012061CD1678DD2 No fault code found. Readiness: 0 0 1 1 1 ------------------------------------------------------------------------------- Address 03: ABS Brakes Labels: 1K0-907-379-MK70.lbl Part No: 1K0 907 379 P Component: ASR FRONT MK70 0105 Coding: 0017106 Shop #: WSC 35110 377 00159 VCID: 3FDABDCCEB7D7D339EB-806A 1 Fault Found: 00668 - Supply Voltage Terminal 30 002 - Lower Limit Exceeded - Intermittent ------------------------------------------------------------------------------- Address 08: Auto HVAC Labels: 1K0-820-047.lbl Part No: 2K0 820 047 AF Component: Climatic PQ35 120 0606 Shop #: WSC 00000 000 00000 VCID: 698E4394C579238310F-803C No fault code found. ------------------------------------------------------------------------------- Address 09: Cent. Elect. Labels:. 1K0-937-049-21-B.lbl Part No SW: 1K0 937 049 AA HW: 1K0 937 049 AA Component: Bordnetz-SG H37 0501 Revision: 00H37000 Serial number: 00000006170591 Coding: 00884F010004100000000000000000000008B1065C Shop #: WSC 35110 377 08192 VCID: 6E843088FC97C4BB45D-803A Subsystem 1 - Part No: 2K2 955 119 C Labels: 1KX-955-119.CLB Component: Wischer 010806 020 0501 Coding: 00038805 Shop #: WSC 35110 1 Fault Found: 01505 - Bulb for Blinkers; Rear Right (M8) 012 - Electrical Fault in Circuit ------------------------------------------------------------------------------- Address 15: Airbags Labels: 6Q0-909-605-VW52.lbl Part No SW: 6Q0 909 605 AH HW: 6Q0 909 605 AH Component: 09 AIRBAG VW52 023 2400 Revision: 04023000 Serial number: 0037TD0BDNR/ Coding: 0012345 Shop #: WSC 35110 377 00159 VCID: 7DA607C4A1F1AF23CC7-8028 No fault code found. ------------------------------------------------------------------------------- Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl Part No SW: 1K0 953 549 AN HW: 1K0 953 549 AN Component: Lenksäulenmodul 035 0070 Coding: 0000001 Shop #: WSC 35110 377 08192 VCID: 7EA400C8ACF7B43BD5D-802A No fault code found. ------------------------------------------------------------------------------- Address 17: Instruments Labels: 1K0-920-xxx-17.lbl Part No SW: 2K0 920 843 A HW: 2K0 920 843 A Component: KOMBIINSTRUMENT VDD 1612 Revision: V0003000 Serial number: VWZ7Z0F7101535 Coding: 0016101 Shop #: WSC 65536 645 577705 VCID: 280806901EF3DA8BCF1-807C No fault code found. ------------------------------------------------------------------------------- Address 19: CAN Gateway Labels:. 1K0-907-530-V2.clb Part No SW: 1K0 907 530 H HW: 1K0 907 951 Component: J533__Gateway H04 0010 Revision: H04 02 Serial number: 19060602001443 Coding: 3D01034007007401 Shop #: WSC 35110 377 00159 VCID: 2C00FA800A0BF6AB2B9-8078 No fault code found. ------------------------------------------------------------------------------- Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb Part No SW: 2K0 920 843 A HW: 2K0 920 843 A Component: IMMO VDD 1612 Revision: V0003000 Serial number: VWZ7Z0F7101535 Shop #: WSC 00000 000 00000 VCID: 280806901EF3DA8BCF1-807C No fault code found. ------------------------------------------------------------------------------- Address 44: Steering Assist Labels: 1Kx-909-144-G2V3.clb Part No: 1K2 909 144 L Component: EPS_ZFLS Kl.140 H07 1806 Shop #: WSC 00999 444 64523 VCID: 3536DFE4D941B763447-8060 No fault code found. ------------------------------------------------------------------------------- Address 56: Radio Labels: 1K0-035-1xx-56.clb Part No: 1K0 035 186 R Component: Radio BVX 020 0032 Coding: 0020200 Shop #: WSC 35110 377 08192 VCID: 3536DFE4D941B763447-8060 2 Faults Found: 00821 - Antenna 2 for Radio (R93) 011 - Open Circuit 00871 - Bass Speaker Front Right (R23) 011 - Open Circuit - Intermittent End----(Elapsed Time: 00:48, VBatt start/end: 11.7V/11.7V. VIgn 11.7V)----- Sunday,12,December,2021,11:25:20:03100 VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64 VCDS Version: 21.9.0.2 (x64) HEX-V2 CB: 0.4555.4 Data version: 20210903 DS330.0 www.Ross-Tech.com Dealer/Shop Name: Andre Venter VIN: WV1ZZZ2KZ7X041867 License Plate: ANDRE3 Mileage: 283690km-176276mi Repair Order: andre3 Address 01: Engine Control Module Part Number: 03G 906 016 DM Component and/or Version: R4 1,9L EDC 0000SG 6045 Software Coding: 0050071 Work Shop Code: WSC 35110 VCID: 71BE2BF4EDB9DB4358F-5184 Advanced Identification Serial number: VWZ7Z0F7101535 Identification: BPG-810 Revision: 12345678 Date: 14.09.06 Test stand number: 1876 Manufacturer number: 0049 Flash Status Programming Attempts: 0 Successful Attempts: 0 Programming Status: 00000000 Required Conditions: 00000101 Flash Tool Code: 00000 000 00000 Flash Date: 00.00.00 Software P0101 U85B6 Misc. Hardware number: 028 101 188 2 Car Info Chassis Number: WV1ZZZ2KZ7X041867 VCDS Info: VCID: 71BE2BF4EDB9DB4358F-5184 Labels: 03G-906-016-BKC.CLB Readiness: No script available -------------------------------------------------------------------------------- -------------------------------------------------------------------------------- Address 01: Engine (03G 906 016 DM) 11:26:56 Group 004: Pump-Jet Valves 903 /min Engine Speed (G28) 6.5 °BTDC Injection Start (specified) 7.1°KW Injection Duration (specified) 0.0°KW Torsion Value 11:26:56 Group 013: Idle Stabilization (Injection Quantity Deviation) -1.04 mg/str Injection Quantity Deviation Cyl. 1 1.74 mg/str Injection Quantity Deviation Cyl. 2 2.59 mg/str Injection Quantity Deviation Cyl. 3 -3.01 mg/str Injection Quantity Deviation Cyl. 4 11:26:56 Group 023: Injector Switch Time Deviation -26.0 Switch Time Deviat. Cylinder 1 -94.0 Switch Time Deviat. Cylinder 2 -60.0 Switch Time Deviat. Cylinder 3 -96.0 Switch Time Deviat. Cylinder 4 -------------------------------------------------------------------------------- -------------------------------------------------------------------------------- Address 01: Engine (03G 906 016 DM) 11:39:41 903 /min Engine Speed (G28) 10.7 mg/str Injection Quantity 8.2°KW Injection Duration (specified) 4.0 °BTDC Injection Start (specified) 0.0°KW Torsion Value 0.0 km/h Vehicle Speed (actual) 826.2 mbar Atmospheric Pressure 703.8 mbar Boost Pressure (actual) -0.07 mg/str Injection Quantity Deviation Cyl. 1 2.38 mg/str Injection Quantity Deviation Cyl. 2 1.20 mg/str Injection Quantity Deviation Cyl. 3 -3.01 mg/str Injection Quantity Deviation Cyl. 4 Dec 12, 2021 #2

Uwe

Benevolent Dictator

Administrator Joined Jan 29, 2014 Messages 58,727 Reaction score 39,631 Location USA VCDS Serial number HC100001

LocomotiveR1 said: I now need to do the injector adaption Click to expand...

This looks to be a PD engine, not a Common-Rail. That means there's no injector adaptation/coding. If the turbo isn't making boost, then the there isn't as much air in the cylinders as the ECU expects, and the black smoke (a sign of an excessively rich mixture in a diesel) isn't entirely unexpected. However, I would expect to see a boost-related DTC... MVB 011 should show you both specified (by the ECU) and actual (measured) manifold pressure.

LocomotiveR1 said: I can supply a log (*.csv) of a drive I took but an unsure how to attach the file. Click to expand...

You can't attach files here. Please open the log with Notepad, copy the contents, and paste them in-line. -Uwe- Dec 13, 2021 #3

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Hi Uwe Many thanks for the reply. Yes it's a PD engine , a BJB. It seems I am unable to get a decent copy of the log in Notepad. As soon as I copy the *.csv log the columns move making the data look confusing. Soon as I get that to work I will post it. The DTC I get is attached below. Code: copy 16683 - Boost Pressure Regulation P0299 - 000 - Control Range Not Reached Freeze Frame: RPM: 2310 /min Torque: 178.0 Nm Speed: 99.0 km/h Load: 56.9 % Voltage: 14.06 V Bin. Bits: 11000000 Absolute Pres.: 1897.2 mbar Absolute Pres.: 1428.0 mbar Readiness: 0 0 1 1 1 Kind regards Andre Dec 14, 2021 #4

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 My issue, it cuts the right hand side values. :-(. I will do each log individually and see if it will show then ... ( newbie forum issues , apologies) regards Andre Code: copy Sunday 12 December 2021 11:27:21:03100-VCID:71BE2BF4EDB9DB4358F-5184 VCDS Version: Release 21.9.0 (x64) Data version: 20210903 DS330.0 03G 906 016 DM R4 1.9L EDC 0000SG 6045 Group A: '004 Group B: '013 Group C: '023 Engine Speed Injection Start Injection Duration Torsion Value Injection Quantity Injection Quantity Injection Quantity Injection Quantity Switch Time Deviat. Switch Time Deviat. Switch Time Deviat. Switch Time Deviat. TIME (G28) (specified) (specified) TIME Deviation Cyl. 1 Deviation Cyl. 2 Deviation Cyl. 3 Deviation Cyl. 4 TIME Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Marker STAMP /min °BTDC °KW °KW STAMP mg/str mg/str mg/str mg/str STAMP 0.02 903 6.5 7.7 0 0.26 -0.66 1.74 2.21 -3.01 0.55 -26 -92 -60 -96 0.83 903 6.5 7.1 0 1.1 -0.66 1.79 2.19 -3.01 1.36 -23 -92 -61 -94 1.63 903 6.5 7.1 0 1.9 -0.66 1.81 2.16 -3.01 2.17 -23 -92 -64 -97 2.45 903 6.5 7.7 0 2.72 -0.68 1.84 2.16 -3.01 2.99 -27 -90 -63 -95 3.25 1344 8.4 8.2 0 3.52 -0.66 0.89 2.16 -3.01 3.79 -11 -89 -55 -99 4.05 1344 8.7 8.2 0 4.32 -0.42 1.08 2.35 -3.01 4.59 1 -74 -50 -93 4.84 1638 7.4 8.2 0 5.11 -0.42 1.08 2.35 -3.01 5.38 5 -70 -44 -106 5.65 1701 7.8 7.7 0 5.92 -0.42 1.08 2.35 -3.01 6.18 5 -69 -36 -100 6.45 1701 7.4 7.7 0 6.73 -0.42 1.08 2.35 -3.01 7.01 5 -63 -31 -100 7.29 2226 11.2 9.7 0 7.58 -0.42 1.08 2.35 -3.01 7.85 25 -42 -2 -83 8.11 2709 13 9.2 0 8.38 -0.42 1.08 2.35 -3.01 8.65 38 -26 5 -82 8.92 2982 15.2 3.1 0 9.18 -0.42 1.08 2.35 -3.01 9.44 30 -34 3 -82 9.71 2121 9.6 6.6 0 9.97 -0.42 1.08 2.35 -3.01 10.24 14 -58 -22 -99 10.51 2100 9.9 7.7 0 10.79 -0.42 1.08 2.35 -3.01 11.04 15 -56 -23 -99 11.32 2121 10.2 7.7 0 11.59 -0.42 1.08 2.35 -3.01 11.86 17 -59 -18 -94 12.13 2163 10.2 7.7 0 12.39 -0.42 1.08 2.35 -3.01 12.66 15 -57 -18 -94 12.93 2184 10.5 7.7 0 13.2 -0.42 1.08 2.35 -3.01 13.48 15 -56 -15 -92 13.74 2226 10.5 7.7 0 14 -0.42 1.08 2.35 -3.01 14.27 17 -55 -15 -98 14.54 2247 10.9 7.1 0 14.8 -0.42 1.08 2.35 -3.01 15.08 16 -56 -15 -98 15.36 2247 10.9 7.1 0 15.63 -0.42 1.08 2.35 -3.01 15.89 20 -56 -15 -97 16.16 2310 11.5 7.7 0 16.43 -0.42 1.08 2.35 -3.01 16.7 17 -55 -15 -93 16.97 1449 5.6 0.5 0 17.24 -0.4 1.08 2.35 -3.01 17.5 -7 -81 -33 -95 17.77 882 6.2 7.7 0 18.04 -0.49 1.04 2.45 -2.94 18.3 -25 -97 -54 -102 18.57 882 6.2 7.7 0 18.84 -0.54 1.13 2.45 -3.01 19.11 -27 -97 -63 -98 19.39 903 6.2 7.7 0 19.67 -0.59 1.22 2.52 -3.01 19.95 -25 -93 -66 -94 Dec 14, 2021 #5

Uwe

Benevolent Dictator

Administrator Joined Jan 29, 2014 Messages 58,727 Reaction score 39,631 Location USA VCDS Serial number HC100001

LocomotiveR1 said: The DTC I get is attached below. Click to expand...

For boost pressure, you need to start with MVB 011. -Uwe- Dec 14, 2021 #6

JMR

Professional User

Professional VCDS User Joined Sep 27, 2021 Messages 4,248 Reaction score 2,553 Location Romania VCDS Serial number C?ID=432218

LocomotiveR1 said: Hi Uwe Many thanks for the reply. Yes it's a PD engine , a BJB. It seems I am unable to get a decent copy of the log in Notepad. As soon as I copy the *.csv log the columns move making the data look confusing. Soon as I get that to work I will post it. The DTC I get is attached below. Code: copy 16683 - Boost Pressure Regulation P0299 - 000 - Control Range Not Reached Freeze Frame: RPM: 2310 /min Torque: 178.0 Nm Speed: 99.0 km/h Load: 56.9 % Voltage: 14.06 V Bin. Bits: 11000000 Absolute Pres.: 1897.2 mbar Absolute Pres.: 1428.0 mbar Readiness: 0 0 1 1 1 Kind regards Andre Click to expand...

Just fixed today ( finally ) this problem on a VW Touareg 2008 2.5 TDI BPE 128 KW . Turbo was bad ( broken impeller ) , client repaired turbo, installed on the car, the above dtc appeared when car was accelerated between 2500-3000 rpm. Everything checked out ( vaacum , hoses, intercooler, egr ) . Car had a BAD turbo pressure control solenoid/valve. Changed it with original part number, car ALIVE ,pulls like crazy , turbo hose inflating like a baloon and no codes. ( took us 2 days of different methods to flush out the problem ). Iwould've post a scan but it's on my touch screen work tablet and for some reason the copy paste function does not work for this forum. The funny thing is that we initially suspected the turbo controller and we did changed it , but it was a WRONG part number and it didn't work. Luckily for us, there are plenty of those tanks around here and we swapped one from a working Touareg with and original turbo control solenoid. EDIT : is it me or that PD injector is as BAD as they can be . Can't make out at this hour which one is it because the values are all askew.? -3.01 deviation? Seems like it's dead !! IF i read it right , it's injector 4, 2 and 3 also does not look too good . Last edited: Dec 14, 2021 Dec 30, 2021 #7

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Hi Apologies its taken this long to get the data files sorted into Notepad. I've attached Group 23 and Group 13 logs. Both at various throttle positions whilst driving. The scan gives me the same "P0299" Boost not reached, but this would be as the engine is not getting enough diesel to burn to spin the turbo ( my theory :-) ). I controlled the turbo waste gate manually (with a vacuum pump), logged the boost pressure and it worked fine. Ouestions: 1) What are the limits for the " Injection Quantity Deviation" or where it should be? 2) Same as above but "Switch Time deviation" limits. I had the PD's removed and sent to get tested at a diesel injector facility. Looks like i wasted my cash as I'm sure they my issue, either 1 , 2 or all of them. Any help or advice please. Andre Code: copy VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64 VCDS Version: 21.9.0.2 (x64) HEX-V2 CB: 0.4555.4 Data version: 20210903 DS330.0 www.Ross-Tech.com Dealer/Shop Name: Andre Venter VIN: WV1ZZZ2KZ7X041867 License Plate: ANDRE4 Mileage: 283700km-176283mi Repair Order: andre4 Chassis Type: 2K (1K0) Scan: 01 03 08 09 15 16 17 19 25 44 56 VIN: WV1ZZZ2KZ7X041867 Mileage: 283700km-176283miles 00-Steering Angle Sensor -- Status: OK 0000 01-Engine -- Status: Malfunction 0010 03-ABS Brakes -- Status: Malfunction 0010 08-Auto HVAC -- Status: OK 0000 09-Cent. Elect. -- Status: Malfunction 0010 15-Airbags -- Status: OK 0000 16-Steering wheel -- Status: OK 0000 17-Instruments -- Status: OK 0000 19-CAN Gateway -- Status: OK 0000 25-Immobilizer -- Status: OK 0000 44-Steering Assist -- Status: OK 0000 56-Radio -- Status: Malfunction 0010 ------------------------------------------------------------------------------- Address 01: Engine Labels: 03G-906-016-BKC.clb Part No SW: 03G 906 016 DM HW: 028 101 188 2 Component: R4 1,9L EDC 0000SG 6045 Revision: 12345678 Serial number: VWZ7Z0F7101535 Coding: 0050071 Shop #: WSC 35110 377 00159 VCID: 71BE2BF4EDA9DB4358F-8024 VINID: 9E606AAAA09BA87A001012061CD1678DD2 1 Fault Found: 16683 - Boost Pressure Regulation P0299 - 000 - Control Range Not Reached Freeze Frame: RPM: 2541 /min Torque: 150.0 Nm Speed: 59.0 km/h Load: 70.2 % Voltage: 14.14 V Bin. Bits: 11000000 Absolute Pres.: 1917.6 mbar Absolute Pres.: 724.2 mbar Readiness: 0 0 0 0 1 ------------------------------------------------------------------------------- Address 03: ABS Brakes Labels: 1K0-907-379-MK70.lbl Part No: 1K0 907 379 P Component: ASR FRONT MK70 0105 Coding: 0017106 Shop #: WSC 35110 377 00159 VCID: 3FDABDCCEB7D7D339EB-806A 1 Fault Found: 00668 - Supply Voltage Terminal 30 002 - Lower Limit Exceeded - Intermittent ------------------------------------------------------------------------------- Address 08: Auto HVAC Labels: 1K0-820-047.lbl Part No: 2K0 820 047 AF Component: Climatic PQ35 120 0606 Shop #: WSC 00000 000 00000 VCID: 698E4394C579238310F-803C No fault code found. ------------------------------------------------------------------------------- Address 09: Cent. Elect. Labels:. 1K0-937-049-21-B.lbl Part No SW: 1K0 937 049 AA HW: 1K0 937 049 AA Component: Bordnetz-SG H37 0501 Revision: 00H37000 Serial number: 00000006170591 Coding: 00884F010004100000000000000000000008B1065C Shop #: WSC 35110 377 08192 VCID: 6E843088FC97C4BB45D-803A Subsystem 1 - Part No: 2K2 955 119 C Labels: 1KX-955-119.CLB Component: Wischer 010806 020 0501 Coding: 00038805 Shop #: WSC 35110 1 Fault Found: 01505 - Bulb for Blinkers; Rear Right (M8) 012 - Electrical Fault in Circuit ------------------------------------------------------------------------------- Address 15: Airbags Labels: 6Q0-909-605-VW52.lbl Part No SW: 6Q0 909 605 AH HW: 6Q0 909 605 AH Component: 09 AIRBAG VW52 023 2400 Revision: 04023000 Serial number: 0037TD0BDNR/ Coding: 0012345 Shop #: WSC 35110 377 00159 VCID: 7DA607C4A1F1AF23CC7-8028 No fault code found. ------------------------------------------------------------------------------- Address 16: Steering wheel Labels: 1K0-953-549-MY8.lbl Part No SW: 1K0 953 549 AN HW: 1K0 953 549 AN Component: Lenksäulenmodul 035 0070 Coding: 0000001 Shop #: WSC 35110 377 08192 VCID: 7EA400C8ACF7B43BD5D-802A No fault code found. ------------------------------------------------------------------------------- Address 17: Instruments Labels: 1K0-920-xxx-17.lbl Part No SW: 2K0 920 843 A HW: 2K0 920 843 A Component: KOMBIINSTRUMENT VDD 1612 Revision: V0003000 Serial number: VWZ7Z0F7101535 Coding: 0016101 Shop #: WSC 65536 645 577705 VCID: 280806901EF3DA8BCF1-807C No fault code found. ------------------------------------------------------------------------------- Address 19: CAN Gateway Labels:. 1K0-907-530-V2.clb Part No SW: 1K0 907 530 H HW: 1K0 907 951 Component: J533__Gateway H04 0010 Revision: H04 02 Serial number: 19060602001443 Coding: 3D01034007007401 Shop #: WSC 35110 377 00159 VCID: 2C00FA800A0BF6AB2B9-8078 No fault code found. ------------------------------------------------------------------------------- Address 25: Immobilizer Labels: 1K0-920-xxx-25.clb Part No SW: 2K0 920 843 A HW: 2K0 920 843 A Component: IMMO VDD 1612 Revision: V0003000 Serial number: VWZ7Z0F7101535 Shop #: WSC 00000 000 00000 VCID: 280806901EF3DA8BCF1-807C No fault code found. ------------------------------------------------------------------------------- Address 44: Steering Assist Labels: 1Kx-909-144-G2V3.clb Part No: 1K2 909 144 L Component: EPS_ZFLS Kl.140 H07 1806 Shop #: WSC 00999 444 64523 VCID: 3536DFE4D941B763447-8060 No fault code found. ------------------------------------------------------------------------------- Address 56: Radio Labels: 1K0-035-1xx-56.clb Part No: 1K0 035 186 R Component: Radio BVX 020 0032 Coding: 0020200 Shop #: WSC 35110 377 08192 VCID: 3536DFE4D941B763447-8060 2 Faults Found: 00821 - Antenna 2 for Radio (R93) 011 - Open Circuit 00871 - Bass Speaker Front Right (R23) 011 - Open Circuit - Intermittent End----------(Elapsed Time: 00:49, VBatt start/end: 12.7V/12.4V)----------- Code: copy Thursday 30 December 2021 14:26:00:03100-VCID:71BE2BF4EDA9DB4358F-8024 VCDS Version: Release 21.9.0 (x64) Data version: 20210903 DS330.0 03G 906 016 DM R4 1.9L EDC 0000SG 6045 Group A: '002 Group C: '023 Engine Speed Accel. Pedal Pos. Switch Time Deviat. Switch Time Deviat. Switch Time Deviat. Switch Time Deviat. TIME (G28) Sensor 1 (G79) Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 STAMP /min % 1.74 1050 75.3 32 -89 -60 -107 2.27 1722 86.3 37 -88 -58 -114 2.81 1659 90.2 34 -86 -63 -110 3.33 1407 84.3 32 -90 -59 -104 3.81 1218 69.4 30 -91 -58 -101 4.32 1008 69.4 21 -101 -63 -108 4.81 777 74.1 20 -103 -69 -109 5.31 882 75.7 21 -104 -72 -110 5.84 1050 76.1 19 -97 -65 -107 6.35 1155 82.4 33 -94 -59 -103 6.86 1176 82.4 32 -90 -56 -101 7.38 1260 82.4 34 -88 -56 -98 7.88 1344 80.4 32 -85 -57 -102 8.37 1449 72.9 31 -88 -60 -110 8.86 1575 70.6 35 -84 -62 -109 9.37 1701 65.5 36 -84 -63 -115 9.89 1827 65.1 33 -85 -57 -117 10.4 1995 56.9 43 -75 -52 -116 10.92 2142 52.2 49 -72 -49 -113 11.43 2247 50.6 47 -67 -49 -112 11.94 2352 50.6 51 -62 -42 -107 12.46 2436 50.6 54 -56 -41 -103 12.98 2478 0 48 -67 -47 -109 13.49 1722 0 48 -67 -47 -109 14.03 1029 0 22 -89 -56 -108 14.56 945 6.3 20 -89 -59 -108 Code: copy December 2021 R4 1.9L EDC 0000SG 6045 Group'002 Group '013 Engine Speed Accel. Pedal Pos. Injection Quantity Injection Quantity Injection Quantity Injection Quantity (G28) Sensor 1 (G79) Deviation Cyl. 1 Deviation Cyl. 2 Deviation Cyl. 3 Deviation Cyl. 4 /min % mg/str mg/str mg/str mg/str 903 0 -1.04 2.66 2.99 -3.01 903 0 -1.04 2.64 2.99 -3.01 903 0 -1.04 2.61 2.99 -3.01 903 0 -1.01 2.59 2.99 -3.01 903 0 -1.01 2.54 2.99 -3.01 1470 59.2 -1.01 2.56 2.99 -3.01 1764 76.5 -1.01 2.56 2.99 -3.01 1638 76.5 -1.01 2.56 2.99 -3.01 1533 76.5 -0.99 2.56 2.99 -3.01 1470 76.9 -0.96 2.56 2.99 -3.01 1386 76.9 -0.94 2.56 2.96 -3.01 1281 77.6 -0.96 2.59 2.96 -3.01 1365 77.6 -0.99 2.61 2.96 -3.01 1491 81.6 -0.99 2.64 2.94 -3.01 1680 83.1 -0.99 2.64 2.94 -3.01 1827 83.9 -0.99 2.64 2.94 -3.01 1995 88.2 -0.99 2.64 2.94 -3.01 2184 92.5 -0.99 2.64 2.94 -3.01 2373 96.1 -0.99 2.64 2.94 -3.01 2520 100.0 -0.99 2.64 2.94 -3.01 2667 100.0 -0.99 2.64 2.94 -3.01 2772 37.6 -0.99 2.64 2.94 -3.01 1575 90.2 -0.99 2.64 2.94 -3.01 1596 96.1 -0.99 2.64 2.94 -3.01 1659 98.0 -0.99 2.64 2.94 -3.01 1722 98.0 -0.99 2.64 2.94 -3.01 945 0 -0.52 1.11 0.94 -1.51 840 0 -0.54 1.15 0.99 -1.58 882 0 -0.56 1.36 1.08 -1.88 882 0 -0.64 1.62 1.22 -2.21 882 0 -0.68 1.88 1.36 -2.52 882 0 -0.71 2.12 1.44 -2.82 903 0 -0.75 2.28 1.58 -3.01 1218 31 -0.78 2.38 1.62 -3.01 1449 70.2 -0.75 2.4 1.65 -3.01 1365 71.8 -0.75 2.4 1.65 -3.01 1344 81.2 -0.75 2.42 1.67 -3.01 1512 88.6 -0.75 2.42 1.67 -3.01 1638 94.9 -0.75 2.42 1.67 -3.01 1806 95.7 -0.75 2.42 1.67 -3.01 1995 98.8 -0.75 2.42 1.67 -3.01 2163 98.8 -0.75 2.42 1.67 -3.01 2436 99.2 -0.75 2.42 1.67 -3.01 2331 0 -0.75 2.42 1.67 -3.01 1638 27.8 -0.73 2.42 1.67 -3.01 1470 82.7 -0.71 2.42 1.72 -3.01 1533 90.2 -0.71 2.42 1.72 -3.01 1575 91.8 -0.71 2.42 1.72 -3.01 1680 92.9 -0.71 2.42 1.72 -3.01 1764 93.3 -0.71 2.42 1.72 -3.01 1827 93.3 -0.71 2.42 1.72 -3.01 1890 93.7 -0.71 2.42 1.72 -3.01 1050 66.7 -0.99 1.25 0.99 -1.25 1113 66.7 -1.06 1.34 1.04 -1.29 1176 66.7 -1.13 1.41 1.11 -1.41 1239 66.7 -1.18 1.51 1.18 -1.51 1302 66.7 -1.2 1.55 1.22 -1.58 1386 66.7 -1.18 1.58 1.25 -1.65 1449 66.3 -1.15 1.6 1.27 -1.74 1533 66.3 -1.15 1.6 1.27 -1.72 1617 66.3 -1.15 1.6 1.27 -1.72 1680 66.3 -1.15 1.6 1.27 -1.72 1785 66.3 -1.15 1.6 1.27 -1.72 1848 66.3 -1.15 1.6 1.27 -1.72 1953 66.3 -1.15 1.6 1.27 -1.72 2016 66.3 -1.15 1.6 1.27 -1.72 2100 63.5 -1.15 1.6 1.27 -1.72 2205 63.5 -1.15 1.6 1.27 -1.72 2310 63.5 -1.15 1.6 1.27 -1.72 2415 62 -1.15 1.6 1.27 -1.72 2331 6.3 -1.15 1.6 1.27 -1.72 2373 1.6 -1.15 1.6 1.27 -1.72 2310 0 -1.15 1.6 1.27 -1.72 Dec 30, 2021 #8

JMR

Professional User

Professional VCDS User Joined Sep 27, 2021 Messages 4,248 Reaction score 2,553 Location Romania VCDS Serial number C?ID=432218

LocomotiveR1 said: Hi Apologies its taken this long to get the data files sorted into Notepad. I've attached Group 23 and Group 13 logs. Both at various throttle positions whilst driving. The scan gives me the same "P0299" Boost not reached, but this would be as the engine is not getting enough diesel to burn to spin the turbo ( my theory :-) ). I controlled the turbo waste gate manually (with a vacuum pump), logged the boost pressure and it worked fine. Ouestions: 1) What are the limits for the " Injection Quantity Deviation" or where it should be? 2) Same as above but "Switch Time deviation" limits. I had the PD's removed and sent to get tested at a diesel injector facility. Looks like i wasted my cash as I'm sure they my issue, either 1 , 2 or all of them. Any help or advice please. Andre Click to expand...

for injector rates comparison please see this link : PD units Inector rates

LocomotiveR1 said: 16683 - Boost Pressure Regulation Click to expand...

LocomotiveR1 said: P0299 - 000 - Control Range Not Reached Freeze Frame: RPM: 2310 /min Torque: 178.0 Nm Speed: 99.0 km/h Load: 56.9 % Voltage: 14.06 V Bin. Bits: 11000000 Absolute Pres.: 1897.2 mbar Absolute Pres.: 1428.0 mbar Readiness: 0 0 1 1 1 Click to expand...

did you try a new/used boost pressure solenoid? This is how I've fixed my problem but it seems that you din not read my post :

JMR said: Just fixed today ( finally ) this problem on a VW Touareg 2008 2.5 TDI BPE 128 KW . Turbo was bad ( broken impeller ) , client repaired turbo, installed on the car, the above dtc appeared when car was accelerated between 2500-3000 rpm. Everything checked out ( vaacum , hoses, intercooler, egr ) . Car had a BAD turbo pressure control solenoid/valve. Changed it with original part number, car ALIVE ,pulls like crazy , turbo hose inflating like a baloon and no codes. ( took us 2 days of different methods to flush out the problem ). Iwould've post a scan but it's on my touch screen work tablet and for some reason the copy paste function does not work for this forum. The funny thing is that we initially suspected the turbo controller and we did changed it , but it was a WRONG part number and it didn't work. Luckily for us, there are plenty of those tanks around here and we swapped one from a working Touareg with and original turbo control solenoid. EDIT : is it me or that PD injector is as BAD as they can be . Can't make out at this hour which one is it because the values are all askew.? -3.01 deviation? Seems like it's dead !! IF i read it right , it's injector 4, 2 and 3 also does not look too good . Click to expand...

Dec 30, 2021 #9

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Hi Yes i did read the post, and tried a used boost pressure solenoid and every other sensor I could borrow. The PD injector post was really informative but this is a BJB motor and was not sure if the figures were similar to the engines mentioned there ( subsequently found some on a Tdi forum and the ones on my caddy look terrible). Steep learning curve this diesel stuff. Small, high reving petrol engines with software I'm more at home with ( Woolich, Yoshimura, 2D and YEC) I can manage, here I'm an infant :-). Appreciate the help and comments. Kind regards Andre Dec 30, 2021 #10

JMR

Professional User

Professional VCDS User Joined Sep 27, 2021 Messages 4,248 Reaction score 2,553 Location Romania VCDS Serial number C?ID=432218

LocomotiveR1 said: he PD injector post was really informative but this is a BJB motor and was not sure if the figures were similar to the engines mentioned there Click to expand...

all pd injector rates should be in that area no matter the engine code have you had the variable geometry of your turbo checked? Did you verify your turbine shaft for wear? stick your fingers in there and see if you can move the shaft like is loose. Your lack of boost has nothing to do with injectors, but more with how much air goes through the MAF , pressure inside intake and stuff like that. Changed the air filter lately ? I've found one halfway inside the MAF pipe once ,if you can believe that. The filter was black with dirt and debris. Last edited: Dec 30, 2021 Dec 30, 2021 #11

JMR

Professional User

Professional VCDS User Joined Sep 27, 2021 Messages 4,248 Reaction score 2,553 Location Romania VCDS Serial number C?ID=432218 get someone to rev your car few times over 3-4000 rpm s and observe the behavior of the turbo hose, does it sucks itself ? Dec 31, 2021 #12

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Morning I removed the turbo and sent it in to get a refresh and test. On the flow bench test it put a good graph after the service. I also blocked off the control vacuum pipe and manually controlled the vacuum. From about 2000RPM the boost climbs and stays there until RPM drops when accelerator is backed off. Bought a new MAF and fitted it. No change. Built an adapter and fitted a pressure gauge to the port on the side of the fuel pump ( tandem pump - vacuum/fuel). Initially at 3000 RPM I measured 3 - 3.2 bar. Bought and fitted a new pump. I now measure 7.2 bar at 3000 RPM. So I got enough pressure to the PD's. Whilst driving although there is no excessive exhaust smoke, no rough running/idle but there is very little power. Intermittently the vehicle "surges" forward, as if there is a blockage which clears or its running on 3 cylinders and the fourth chimes in for that brief moment. I have also done a compression test with all 4 cylinders within an acceptable range . Suppose I need to make an adapter and measure the leak down although if compression is good leakdown is not needed normally. Next is to measure the camshaft. The VW manual I have does not have specifications to check the cam, for example lobe height. Where could I find this? I will check the hose whilst giving the engine a good rev. Many thanks for the help and advice. Kind regards Andre Dec 31, 2021 #13

JMR

Professional User

Professional VCDS User Joined Sep 27, 2021 Messages 4,248 Reaction score 2,553 Location Romania VCDS Serial number C?ID=432218 Seeing how you installed a good but used cylinder head block..have you had that resurfaced and used proper gasket to adjust for the resurfacing ? Jan 2, 2022 #14

LocomotiveR1

Verified VCDS User

Verified Joined Jan 14, 2021 Messages 11 Reaction score 3 Location Edenvale, South Africa VCDS Serial number C?ID=422303 Hi , yes was surface cleaned , checked for true and then squish set with correct gasket. It's going to park in the workshop until I get time to start from scratch and go thru each step. January in our workshop is extremely busy as racing starts 1/2 way thru Feb so my van will wait. :-) Appreciate the help and advice. Andre Status Not open for further replies. Share: Bluesky LinkedIn Share Link

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