OBD Engine Diagnostics: Rough Idle & ESP Analysis

Hello,
The vehicle is a Volkswagen Allroad 2.5 TDI, manufactured in November 2000, with a manual transmission, air conditioning, and 180 horsepower.
Original AKE engine replaced with a BDH engine in 2003 (mileage approximately 213,000 km; the seller claims it had 15,000 km on it); ESP and ECU were not replaced.
11/05: Turbocharger replaced.
now 283,000 km
The last 3,000 kilometers were run in warm conditions using vegetable oil; cold starts were done with diesel (dual-tank conversion).
Chiptuned to approximately 209 horsepower around May 5th.

Problems manifest themselves in the following ways (and this is not a new issue since the introduction of the Pöl system).
When cold (after standing overnight), the engine has extremely poor idling speed (below 2000 RPM) – and it seems to have gotten worse.
Often exhibits an unstable idle speed (at a traffic light); vibrations (engine RPM not entirely constant).
Occasionally, the engine runs unevenly. Sometimes, there are unusual noises during operation (rough).

Then, last Friday, the following happened:
Cold start (diesel engine), unable to rev above 2000 RPM (>driven at 40 km/h in third gear), but after approximately 2 km, everything is back to normal.

Error code stored in memory:

VAG-COM Version: Auto-Intern 303.2
Control unit part number: 4Z7 907 401 A
Component and/or version: G000SG D00
Encoding: 01015
Workshop code: WSC 02325.
Additional information: 00014059 130 106EC150_1.R75364964088
Additional information: 00014059 130 106EC150_1.R75364964088
Two error codes found:
00575 - Intake manifold pressure.
11-00 - Limit exceeded.
00550 - Injection start control.
17-00 - Rule difference.


- deleted, will not reappear.


Würde gern ESP und Motor (ob er überhaupt auf allen Zylindern läuft) checken. ES"D etc."
Theoretically, it could also be related to the transmission and clutch in some cases (causing uneven running), but I consider that rather unlikely.

The error memory is largely clear (only showing errors related to the radio and the leveling system); previous errors have been cleared by the battery management system due to the defective battery.
Errors occur regardless of the fuel type.

The vehicle and its ESP system have 283,000 km (approximately 176,000 miles), while the engine has 85,000 km (approximately 53,000 miles).
The timing belt looks slightly frayed at the edges, but it's not causing any problems so far.


Here's another one: Last week, the service interval unexpectedly decreased from 2400 kilometers to just 100 kilometers in a single day (covering only a few hundred kilometers). I can only imagine that a sensor is either measuring incorrect values or is faulty.
I noticed years ago that the fuel consumption decreases faster on short distances, in off-road conditions, and in snow – but never this quickly. Also, this time I only used the highway; I never drove faster than 140 km/h, mostly around 130 km/h with cruise control.


I have VAG-COM 303.2 and a serial interface.
Logging and display via VAG-Scope are working; tdigraph shows "No data from vag-com. Have you started a group?".
I have created log files for both cold diesel operation and warm partial load (PÖL) operation.
Sure, here is the translation of the text from German to English:

"In addition, please provide 2 screenshots."

" color="red">Bitte keine Links zu externen Dateihostern! a) nerven die zusätzlich notwendigen Klicks, b) Wartezeit, Werbebanner/Werbepopups und notwendige Registrierungen, c) ist nach einiger Zeit die Datei weg und das Thema für andere Leser nutzlos!

Bitte nutze 'Attachment hinzufügen' bzw. das Upload Forum hier.

Oops.

robotroonie wrote:

VAG-COM Version: Auto-Intern 303.2

I don't think you'll be well-received with that, because it's questionable whether you have a legitimate license.

I'm sorry, but I legally acquired the equipment (OBD interface including software with a license) back then (it wasn't cheap). And current versions are supposed to not work with the old serial interface anyway. Otherwise, I would have bought an update long ago. But I might upgrade to a newer USB interface soon.

Hi,

Please provide the text you would like me to translate from German to English. I will only provide the translation, without any explanations.
/search.php

Enter *575* or *550* and select "Error/Knowledge Base" as the category.
Try also using your engine's identification code as an additional search term.

Best regards, Rainer.

Okay, I'll do that now. The DSL connection has been working again for a few hours, so it should be better now. But will searching with the MKB code actually help? My configuration (MKB BDH instead of AKE, original ESP) is probably not very common.
Nevertheless, I don't believe these two entries represent the primary error. These two errors likely originated from last Friday and have only occurred once so far.

However, the actual issues that need to be fixed have been occurring for months.

Is there anything we can learn from the logs?
The EGR valve was deactivated during the engine replacement.
"While logging, the connection was frequently interrupted. Initially, I suspected that the simultaneously running Vagscope software might be the cause, but the communication failures then occurred even when Vagscope wasn't running."
It usually worked again after restarting the engine, but not always.

robotroonie wrote:

And current versions are not supposed to work with the old serial interface anyway.

At the very least, version 311.2 is working, so make sure to update at least up to that version.

robotroonie wrote:

Otherwise, I would have bought an update a long time ago.

Updates have always been and will continue to be free of charge; simply contact your seller or distributor to obtain them.

robotroonie wrote:

The connection frequently dropped during logging. Initially, I suspected the simultaneously running Vagscope, but the communication failures then also occurred even without it being active.

VAG-Scope has no influence on communication; you should check the hardware being used for potential errors and also consult the FAQs for further information.

http://ross-tech.com/vag-com/faq_2.html#2.5

Regarding the actual problem, take a look at the turbocharger boost pressure; you'll likely find something is wrong there, and that those error codes have a reason behind them.

The seller also provided me with version 311.2 when it was released (for free), but something didn't quite work out with the communication regarding that. I thought that the very latest versions might no longer be included in the update entitlement.

I visited a diesel specialist; the conclusion was:
LMM, Ladeluftkühler, Turbo sind OK. ESP malfunction.
"During the test drive, the intake air temperature reached up to 2438; the target maximum is 2300. So, it's okay (probably a bit higher even after chipping). Unfortunately, I'm not very knowledgeable about this subject."
But according to my own logs, the pressure also goes up to 2560 (or is that the target pressure, and is the second column the actual pressure?). The label file is missing here.

Assuming that the first column represents the target values and the second column represents the actual values, it's true that they don't match. But why was this different today? Or did a professional make a mistake?
Could it be due to values measured by VCDS that are not perfectly synchronized in time?

Hi,

When I click on your download link, I always see advertisements above the link, and I can't seem to get rid of them.
Meaning of the measured values:
http://www.dieselschrauber.de/Solldaten_6_Zylinder_VE.html

Best regards, Rainer.

I tried it myself. It works, but it's cumbersome (you have to wait for a timer and click links). It's difficult without English skills. Therefore, I've now added a new link above from a different hosting provider.

robotroonie wrote:

Version 311.2 was also made available to me by the seller upon release (for free), but something didn't quite work out with the communication regarding it.

Regarding that matter, there is no significant difference between 311.2 and 303.2, which is surprising.

robotroonie wrote:

I thought that the completely new versions would then no longer be included in the update entitlement.

Regarding the completely new ones, you're absolutely right.

robotroonie wrote:

The label file is missing here.

Which features are already included for the AKEs (Application Knowledge Engine), for example, in version 311.2.

robotroonie wrote:

Could it perhaps be due to values measured at slightly different times with the VAG-COM device?

VAG-COM reads data just like any other diagnostic tool; the data comes in complete blocks from the control unit, and there is no time delay involved.

Rainer K. wrote:

...when I click on your download link, I always only see advertisements above the link, and I can't get rid of them.

It works perfectly for me, it just takes a little while to find the correct link.

I believe my English skills are sufficient for your banner farm; not everyone uses the "Winzigweich" web browser.

Unfortunately, the log file is corrupted; please check the search function to see how to do it correctly.

If I had to guess, I'd say the 2.5 TDI engine is just terribly tuned, or how else would you explain those absurdly high boost pressures?

Best regards, Rainer.

Sebastian@OpenOBD wrote:

VAG-COM reads data just like any other diagnostic tool; the data comes in complete blocks from the control unit, and there is no time delay involved.

I just read that information in this forum a little while ago (the suggested solution was to log fewer MMBtu values).

Ich bin nun etwas ratlos. Wirklich ESP? If so -
Which one would be the best replacement to use?
Should it be the original part from AKE (is the part number 059 130 106 E or EX?) or the one from BDH (part numbers are 059 130 106 K / 047 050 6038)? If you only look at the ESP part numbers, is it possible to get a part that doesn't fit your engine?

The technician mentioned earlier that a possible cause for the ESP failure might be that the BDH has different ESDs. However, after checking the ESI, he found that while AKE and BDH have different nozzles, the only difference in the BDH is finer atomization (for Euro4 compliance). The opening pressure, etc., are identical. Therefore, this is not a possible cause for the error.

@Rainer

It's not "my" banner farm, so I can't do anything about a lack of compatibility with non-standard browsers. It was just the first free hosting service I found on Google.

The tuner was recommended by many satisfied customers... well, sort of.
Only if the problems stem from that source would they have had to occur earlier.

As mentioned above, the connection kept dropping frequently during logging. Strangely, this only happened on the Autobahn (highway). It's not a problem with the cable. Possibly the notebook is too weak and/or the amount of data in the log has become too large (with 3 MBytes).
If I have made any other mistakes, please let me know. The search results provide little information on this matter (logging/how to). https://community.dieselschrauber.org/en/viewtopic.php?t=5861&highlight=logging+wie
It can certainly be tested again with a specific driving cycle.

Quote:

The tuner was recommended by many satisfied customers... well, sort of. Only if the problems stem from that source, wouldn't it have had to occur earlier?

Let's put it this way: that software modification, which is already problematic, combined with your somewhat sluggish boost pressure control, will definitely trigger the emergency program.

Furthermore, it would have been better to mention the change in the engine control unit from the beginning, so that people wouldn't have to figure everything out on their own.

Here's a thought: A log recording in the traffic light system or the garage doesn't really make sense if you only experience the problem when accelerating hard and at higher RPMs.

The information about the chip is right at the top (from the beginning).

The log shows: Cold start with diesel engine and driving uphill to the highway. The other two sections are on the highway with a constant speed of up to approximately 150 km/h. So, it's a normal driving cycle without any longer stops. I could also create a log under specific conditions (e.g., a certain RPM in a particular gear, at a constant speed).
I'm not currently driving at significantly faster speeds for extended periods; rather, I'm driving slower (a maximum of 140 km/h).
Around 190-200 km/h (approximately 4000 RPM), a problem occurs ("stuttering"/jerking) that may be related to the exhaust system modification (too much air intake or insufficient fuel supply).
The errors I'm referring to are probably different ones.

The label file with the most appropriate name I have is 4D2-907-401. But I'm not sure if it's compatible. If not, I can rename it.