2.0 TDI engine failure - BMP

Hello,
A friend's Passat 3C is experiencing the following problem:
It starts easily, takes very little gas, and then the engine speed slowly decreases until it stalls.

Okay, I just disconnected the fuel pump in the tank – it's showing the same symptoms. How can I test it? Where are the fuses located?
The tandem pump is a bit damp; could it be defective?

Check the parking sensor; it might be stuck.
Wet tandem pump: Usually, the problem is that the cover screws are not tightened enough or a new gasket is needed. (There was a recall about this, but I don't know exactly which model it concerned).
A clogged DPF (Diesel Particulate Filter) or catalytic converter can cause the same issues.

Quote:

Absteller prüfen, kann gut sein, dass dieser verklebt.

I would rule that out, because it's a controlled throttle valve on the BMP.
(not that old-fashioned pneumatic "lid closed" flap anymore).

Here's a video showing the throttle valve in action:
Okay, I'm ready. Please provide the German text you want me to translate into English.

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Sure, no problem!

For now, I've only removed the air hose so that I can observe the valve when starting the engine – it always remains open, which rules out a problem with the valve itself.

Okay, I'm going to remove the EGR valve now and then try starting it.

Okay, I removed the throttle body so I could have a clear view of the EGR valve. Then, I covered the opening on the EGR valve to block the exhaust flow.

--->Smooth idle, readily accepts throttle input .

Can anything be done to repair the EGR valve, or should it be replaced directly?

Thank you for your help so far.

P.S.: The valve operates electromechanically, right?

Quote:

unobstructed view of the AGR

.

Quote:

Das Ventil funktioniert elektromechanisch, oder?

Um, look at it .

Hose -> not electric
Cable -> electrical.



Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Progress report:

The AGR valve was removed, cleaned, and the housing was taken apart. An electric geared motor drives a crankshaft, which controls the valve lift.
(Works when connected to the power supply.)

The position is also recorded (3 pins for the position sensor, likely inductive since the resistance values do not change).

EDIT: Reinstalled it, but no change. Is the EGR valve specifically protected somehow?

Is there fuel in the tank...?

Otherwise, perhaps you could read the error memory and post the log here.

Hello,

Why not simply record the air mass and fuel injection amount for a short period?

Best regards, Rainer.

Normally, that's the first thing I do. So far, my self-built interface (for a Golf 3) has been sufficient.

That's why I'm currently in contact with Rainer, because VCDS is now really necessary and it's on its way!

Okay, I finally got my VCDS license .

I've now driven about 100 km with the EGR system deactivated (electrically locked and cables disconnected) without any problems, and then the engine went into limp mode.

Reconnected the EGR valve at home, started the engine (which turned off after a few seconds), and read the error codes:


Friday, September 26, 2014, 17:25:53:08608
VCDS version: RKS 12.12.3

Address 01: Engine Control Module
Label file: RKS\03G-906-021-BMM.clb
Control unit part number: 03G 997 021 J. Hardware version: 028 101 211 9.
Component and/or version: R4 2.0L EDC G000SG 3898.
Encoding: 0000072
Operating number: WSC 33786 000 1048576
VCID: 306893D1A302F39E2BD-8065
"One error found:"

008194 - Particle filter, bank 1.
P2002 - 000 - Malfunction - Warning light ON.
Freeze Frame:
Error status: 11100000
Error priority: 1.
Error frequency: 1.
Lost Count: 255
Mileage: 268,526 km
Time: 0.
Date: 2014.09.26
Time: 17:14:06

Freeze Frame:
Speed: 0 RPM.
Speed: 0.0 km/h
(no unit): 4.0
Key ratio: 51.3%
(no unit): 0.00
Temperature: 15.3°C
Time: 4492.8 seconds.


Readiness: 1 1 0 0 1

Hello,

You should reactivate the AGR.

Regarding the particulate filter: Please consider this topic and post a relevant log entry about it...
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.

Let's also check the temperature readings from the sensors on the DPF (Diesel Particulate Filter).

Best regards, Rainer.

I immediately reconnected the AGR valve, but the engine dies after about 5 seconds or less, which prevents me from logging any data.
Attached are the other measurement readings (engine off, but still some residual heat).

The DPF light only came on while driving.

PS: The actuator test for the EGR system goes up to a maximum duty cycle of 30%, is that acceptable?

According to measurement block 68, the DPF is completely clogged, and there may also be another blockage in the exhaust system.

Check if the engine is running normally when you slightly loosen the exhaust pipe from the turbocharger.

Best regards, Rainer.

It's very difficult for me to access the DPF.

Now I've removed the AGR valve and performed an actuator diagnosis – and lo and behold, only a small portion of the travel is being used.

Therefore, I strongly suspect the EGR valve!

I'm happy to upload a video if needed.

Hello,

It's possible that the AGR (Abgasrückführungssystem - exhaust gas recirculation system) is also not working correctly, but that alone won't help you.
Because of the ash mass in the DPF:

dieselschrauber wrote:

Wird der Maximalwert von 60 g erreicht bzw. überschritten ist eine Regeneration nicht mehr zulässig und der Partikelfilter muss ersetzt werden.

Scheduled is:
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.

Videos and other content are always welcome.

Best regards, Rainer.