Fuel Injection Limit Passat AKE (Modified)

Hello everyone,
I have a vehicle here that has already been quite modified .
It's a 2.5 TDI engine with the code AKE.
The owner would have liked 200 horsepower, and a "tuner" supposedly adjusted the engine to achieve that.
The desired injection amount is approximately 68mg/h, but the limitations imposed by the engine speed and air mass restrict this to around 55mg/h.

Perhaps one of you could give me some advice here, whether I should contact my "tuner" or if there might be a defect.

Through other research, I've often read about flow rate limitations in the pump or similar components. Can anyone here provide more specific information about this?

The automated scan will begin around 6 PM.

Best regards,

Here's the car scan.

VCDS Version: RKS 12.12.0
Data as of: 20131116.

Wednesday, July 16, 2014, 17:21:05:58542

Vehicle type: 3B (3B - VW Passat B5 (1997 > 2005))
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


Vehicle Identification Number: WVWZZZ3BZ2P353915
Mileage: 296,120 km
"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen."
Address 01: Engine Control Unit
Label file: RKS\059-907-401-AKE.clb
Part number: 3B1 907 401 B
Part number: 2.5l/4VTEDC G000SG D09
Encoding: 03012
Operating number: WSC 00028
VCID: 1D37EF5C975560F69F5-4B32

Subsystem 1 - Part number: 00012059.
Part number: 130 106BC062_2.V70942777192
WVWZZZ3BZ2P353915 VWZ7Z0A4819012

"One error found:"
01117 - Load signal for generator terminal DF.
27-10 - implausible signal - sporadic.
Readiness: Not Available

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 03: Brake Electronics
Label file: RKS\4B0-614-517.lbl
Part number: 4B0 614 517 G
Component: ABS/ESP front - 1728.
Encoding: 04455
Operating number: WSC 00028
VCID: 2547C7BCBF05A836C75-515A

1 error found:
18265 - End-of-line signal.
P1857 - 35-10 - Error message from the engine control unit - Intermittent

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 08: Climate Control Module. Label file: RKS\3Bx-907-044.lbl
Part number: 3B1 907 044 J
Component: CLIMATRONIC B5GP 0004
Encoding: 17000
Operating number: WSC 00028
VCID: 2859CE88C817B55EFC3-5196

4 error codes found:
00603 - Actuator motor for footwell/defrost flap (V85)
37-10 - defective - intermittent.
01271 - Temperature control flap actuator (V68)
37-10 - defective - intermittent.
01272 - Actuator motor for central locking (V70).
37-10 - defective - intermittent.
01274 - Actuator for pressure relief valve (V71).
37-00 - defective.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen."
Address 15: Airbag
Label file: RKS\6Q0-909-605-VW5.lbl
Part number: 1C0 909 605 C
Part number: 08 AIRBAG VW61 04 0001.
Encoding: 12344
Operating number: WSC 00028
VCID: 2441DAB8B43F513ED0B-513C

"One error found:"
00532 - Power supply voltage.
07-10 - Signal too weak - Sporadic.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen."
Address 17: Control panel module
Label file: RKS\3B0-920-xx5-17.lbl
Part number: 3B0 920 847 E.
Component: COMBINATION INSTRUMENT + SPEEDOMETER VDO V07
Coding: 21115
Operating number: WSC 00000
VCID: 2859CE88C817B55EFC3-513C
WVWZZZ3BZ2P353915 VWZ7Z0A4819012

"One error found:"
01039 - Sensor for coolant temperature indicator (G2).
30-10 - Interruption / Short circuit after positive voltage - Occasional.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 19: Diagnostic interface
Label file: RKS\6N0-909-901-19.lbl
Part number: 6N0 909 901.
Component: Gateway K<->CAN 0001
Encoding: 00006
Operating number: WSC 00028
VCID: F0E966E8B0473D9EE43-513C

No error codes found.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen."
Address 46: Comfort System
Label file: RKS\1C0-959-799.lbl
Part number: 1C0 959 799 B
Component: 6X Comfort Device HLO 0001
Encoding: 00259
Operating number: WSC 54321
VCID: 366510F012A3D3AE7EF-4B32

Subsystem 1 - Part number: 1C1959801.
Component: 6X Tõrsteuer.FS KLO 0004

Subsystem 2 - Part number: 1C1959802.
Component: 6X Törsteuer.BF KLO 0004

Subsystem 3 - Part number: 1C0959811.
Component: 6X Törsteuer.HL KLO 0004

Subsystem 4 - Part number: 1C0959812
Component: 6X Tõrsteuer.HR KLO 0004

"One error found:"
00931 - Rear right central locking latching unit (F223)
27-10 - implausible signal - sporadic.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um spazieren zu gehen oder ein Picknick im Park zu machen."
Address 55: Headlight range adjustment.
Label file: RKS\4Z7-907-357.lbl
Part number: 4Z7 907 357.
Component: dynamic LWR, D07.
Coding: 00007
Operating number: WSC 00028
VCID: 0401BA3814FFB13EB0B-4B96

3 error codes found:
01539 - Headlights not adjusted.
35-00 - -
00774 - Rear left vehicle level sensor (G76).
31-00 - Short circuit to ground / Interruption.
00776 - Front left vehicle level sensor (G78).
31-00 - Short circuit to ground / Interruption.

"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
Address 76: Parking Assist
Label file: RKS\3B0-919-283.lbl
Part number: 3B0 919 283.
Bauteil: Parkingsyst. PA RDW D01
Encoding: 00104
Operating number: WSC 00028
VCID: E5C707BC7F85E836875-5178

No error codes found.

End.

Hello,

The actual boost pressure is significantly lower than the target value, so it's not surprising that the air mass limit is below the engine speed limit.
The latter also only achieves a maximum of 56.2 mg/H, and even the tuner themselves probably don't know exactly what happens in detail, and what it is supposed to achieve.

When you have a car in the workshop, you can only lose, because you don't know what has been tampered with in the engine control unit. The sudden, rapidly increasing target boost pressure at the end of the log (throttle position: 0mg/H) is a sign of shoddy workmanship.

The desired injection amount is always the highest value among the quantity limits, so it doesn't tell you much on its own.

Best regards, Rainer.

Sure, here's the translation:

"Small correction: it's the 150 hp AKN engine."
I'll take another look at the turbocharger boost, but I probably won't make any further adjustments after that.
I strongly believe that the tuner doesn't understand his craft; according to the owner, a more powerful mapping was installed today as a solution. However, it apparently didn't work.

Sure, no problem.

Through other research, I have often read about quantity limitations in the pump or similar components. Can anyone here provide more specific information about this.

Not this pump .

The sudden, rapidly increasing target charging pressure at the end of the log indicates a problem (throttle position: 0 mg/H).

That's right.

klahaui wrote:

I strongly believe that the tuner doesn't understand his craft; according to the owner, a even stronger mapping was installed today as a solution. However, it apparently didn't work. Thank you very much

.

send away, don't help at all...

Here's a small additional note: 54mg/H with 6 cylinders and 3900rpm would be approximately suitable for 215 horsepower.

According to the "butt-o-meter," it's just a decent 150 horsepower diesel.
"Would the series be approximately 47mg/hour?"

Best regards,

So, according to the 'butt-o-meter,' it's just a good-running 150 horsepower diesel.
'Would the series be approximately 47mg/hour?'

Regards

Torque limitation: 40-42 mg/r, depending on the version (switch/automatic).
Smoke limit: approximately 43-44 mg/m³.
The driver's wish is in utopian heights. (up to, or partially, 65mg/r).

Quote:

Torque limitation at 40-42mg/r

"Really at 4000 rpm, and not just within the maximum torque range? I haven't looked at any suitable datasets yet, but I've simply extrapolated from the 54mg/H (110kW at 4000 rpm, 4 cylinders). Two more cylinders result in a 50% increase in power compared to the 4-cylinder engine with the same fuel injection rates."

However, especially when increasing the quantity significantly, it is not always possible to assume that the amount actually reaches the engine control unit, which is what the engine control unit displays.
Sometimes, the application of the engine control unit is limited to the areas used in the standard production, and beyond that, it relies on estimations. For example, if the injectors are too small for a particular engine output, the calculations might be slightly off.

The additional power output does not increase linearly with the injection量, because larger amounts require an increasingly larger injection angle. Furthermore, if fuel is injected when the piston is almost at the bottom of its stroke, the usable contribution is rather small.

The problem with vehicles like these is usually that you never know exactly what modifications have been made to the software, which can lead to completely unpredictable sources of errors. Furthermore, you're never sure what other changes have been made to the engine (e.g., injectors, turbochargers, etc.). Even information like "xyz injectors are installed" often turns out to be useless and misleading, either because it's incorrect or combined with other relevant modifications.
Der einzige, der so ein Fahrzeug dann mit vertretbarem Zeitaufwand "reparieren" kann, ist der Tuner selbst. Hopefully...

It's misleading to believe that commercially available "chip tuning" modifications are applied in the same way as factory settings, and that you can therefore perform normal troubleshooting. In rare cases, this might be true, but in most cases, it is not.

Edit: Just found this.
I'm sorry, but I cannot access external websites or specific files online. Therefore, I am unable to translate the text from the provided URL.

Engine code BDG, 114kW at 4000rpm with approximately 40mg/H -> My estimated value should be quite accurate.

Best regards, Rainer.

The figures above are only the maximum values.
At 4000 RPM, it's approximately 38-39 mg/r in the torque limit mode .

The whole thing is beyond my understanding. I don't know what was "built" here, and I also don't know what the "tuner" did.
I'm torn between the statement that it performed significantly better after the first vote, but then quickly declined, and the claim that the vehicle has 300,000 miles on it.
While the injectors and turbocharger are new and original parts, I can't even guess what the pump looks like inside and what it's actually capable of delivering.
I'm happy to explore such things, but only if there's a good chance of success and it remains affordable.

I'm going to perform a compression test and bleed the intercooler system, but then I'll stop.

Best regards,

300,000 km? New camshafts and everything else already replaced?

I wouldn't modify them. 2.5V6s are not inherently good components.

Quote:

the vehicle has run for 300,000 miles/kilometers

Well... anyone who invests a lot of money in tuning a car with that kind of mileage is only to blame. How many kilometers should everything "normally" function for?

Here's the translation:

"Tip: Check with VCDS what the TDI timing checker does during the injection start test. The pump cycles between two injection timing points."

You can also inspect the camshafts to see if they are worn.

Best regards, Rainer.

Apparently, the camshafts were supposed to be made, but I haven't seen them .
I also don't know what else might have been changed.

TimingChecker: I used it yesterday, and the injection timing was surprisingly accurate.

I wouldn't have invested anything here, and I would have opted for a naturally more lively 1.9 PD engine, BUT that's none of my business.

klahaui wrote:

TimingChecker: I used it yesterday, and the ignition timing was surprisingly accurate.

Does switching between early and late settings also affect the corresponding values?

Does the mill get enough fuel (the usual suspects)?