Passat B5 Solenoid Valve: 2.0, 6.0 & 8.0 Status

Good evening, fellow car enthusiasts.

This is my last chance. My friend came from abroad with his family in a "Passat B5 Diesel" car, but unfortunately, the engine broke down during the journey. We bought a diesel engine block and, with the help of some friends who know what they're doing, we've been working to put it together. It usually works well, as these friends are knowledgeable.
This time, I assembled everything and connected it, but the engine won't start. Years ago, I bought the VCDS software with some friends and always enjoyed helping others (with whatever I could). This time, it's different; the engine doesn't start at all. The software isn't showing any error codes.
The only thing that surprises me is that the solenoid valve status shows 2.0, but when starting, it briefly goes up to 6.0 and then to 8.0. I researched online and found that the solenoid valve control cable might be defective. We replaced it, but there was no improvement. The workshop couldn't help us. ADAC (German Automobile Club) conducted an inspection and the result was that either a common positive or negative wire is missing in the control cable, but unfortunately, they couldn't measure it.
The family doesn't have the money to replace the engine again. Please help me understand how to measure the throttle cable. I have a multimeter. Is there a fuse? Also, a neighbor came and sprayed brake cleaner into the air intake, and the engine started, but only while the cleaner was being sprayed.
Please! I need some advice. Thank you in advance!

Hi Alex!

Please, as always and everywhere as is customary here, perform an Autoscan and upload the results!

Okay, and what EXACTLY caused the previous motor to fail while driving?

Thank you.

Best regards from Munich!

Good morning.

Thank you for the information. I'm going to my colleague's place at 12 o'clock to do a vehicle scan. I'm not sure exactly what happened during the drive, but I need to investigate further. There was a period of black smoke, and then the engine block suffered a mechanical failure.

Hi,

Please, no more experiments with brake cleaner.
Please check the fuel supply, including the pressure of the tandem pump. Are the timing settings correct? Were the common rail injectors properly adjusted?

Best regards, Rainer.

I performed an Autoscan, and I've attached the results. Regarding the control cable, there's 0.5V on the brown wire relative to the negative terminal. The 5-pin wiring from the control unit to the motor is in order (measurements taken).

I have a log file containing the status of solenoid valves. Is it possible to extract any useful information from it?

Diesel is leaking from the fuel filter. That's the hose leading to the high-pressure pump. I can't take measurements after the pump. Is it possible to read this information through the software? The engine was purchased with the pump, and the previous owner said everything was fine.
I assume that it was properly adjusted. Can you see that with the software? Are there any tools that can be used to check? Unfortunately, I'm not a mechanic. I really want to help these people. I'm waiting for your advice every second.

I measured the connectors at the engine control unit. There is a resistance of 0.2 ohms between the brown wire with a green stripe and each of the wires that go to the injectors. Is that normal?

Ignition timing.

Can anyone make sense of this?

Quote:

That's the hose to the high-pressure pump. I can't measure anything after the pump. Is it possible to read that out through the software?

Unfortunately, the OBD-2 ignition timing data is not available.

You can check the engine control unit (ECU) to see what coolant temperature (measuring block 7) is displayed, and this value should be correct. Be aware that if the ECU measures a coolant temperature that is too high, the approximately 190 rpm shown in the Screenshot will NOT be sufficient to allow the engine to start.
For further attempts, to achieve the maximum starting amount, you should leave the coolant temperature sensor plug disconnected.

Regarding PD solenoid valves:

Quote:

018,0,Magnet valve status. ; 000 = Error-free operation. ; 002 = Setting during trigger process. ; 004 = Small injection amount or valve OFF. ; 008 = Energy limits/maximum current reached. ; 014 = Injector valve coil: Short circuit to ground. Valve closing time (beginning of injection period = BIP) implausible (outside of the regulation range). ; 032 = Sampling rate too low. ; 064 = Conversion error. ; 128 = Keine Schließzeitidentifikation (Begin of Injection Period = BIP) möglich (Motor AUS ODER elektr. Fehler)

Best regards, Rainer.

Thank you, Rainer, for your help. Unfortunately, the engine remains silent. Tomorrow, an ADAC employee will bring a used engine control unit for testing. He measured the wiring and found that signals are only present when the connector at the cylinder head is disconnected; however, he cannot measure any signals when the connector is reconnected. He suspects there might be a problem with the control unit. It's dark and late. I'm going home. Let's see what tomorrow brings. I am very grateful to you all.

What exactly was replaced in the engine? Just the block, or also the cylinder head including the PDE (pump nozzle injector)?
Make sure the wrong PDEs aren't included in the final product!

Thanks for the information. Actually, the engine block with cylinder head and PDE (high-pressure fuel pump) were replaced. The engine control unit is still the old one. The problem is how to find out if the injectors are compatible with the control unit? Is there a rule? I was also wondering why the solenoid valves are going to state 8.0.

Can it be recognized visually?

Hi,

You cannot check the fuel pressure in the fuel line using the OBD system for this engine. You need a pressure gauge with the correct fitting. There is a test port on the back of the tandem pump. You need to remove the sealing screw and then connect the pressure gauge. For the Passat 3BG, you will need to remove the intercooler piping for this. However, only target values are known for specific engine speeds, so the engine needs to be running. Before doing that, however, repair the leak on the filter that you mentioned.
I've attached a picture of the pressure gauge so you can get a general idea of what it looks like. The part is called VAS 5187.
You can also measure the resistance between the two contacts on the pump-injector units. The target value is 0.5 ohms. Furthermore, in the wiring harness in the cylinder head, there is one brown and one colored wire for each injector. Disconnect the pump-injector connectors and measure the voltage between each brown wire and ground (cylinder head) with the ignition switched on. The target value is 0.1-0.4 volts. Afterwards, clear the error code that will inevitably be set.
You can also check for cable breaks between the PDE (pressure differential sensor) and the control unit. However, based on experience, this is unlikely to be the cause with this model.
If you are replacing the engine control unit, how do you do it? Do you have the PIN for the immobilizer?
Is the timing belt installed correctly?

I completely agree with the previous poster. The pump nozzle units of generation 1.1 and 1.3 look identical and can be easily swapped with each other. However, the electrical component is not compatible. If you install one in a car where it doesn't belong, you will have problems. This can range from the car not starting to running roughly. I can quickly check this if you send me the vehicle's registration number and the part number of the injectors. I just need to remove the valve cover. The part number is on the solenoid valve. See the picture.

Code:

Wenn ihr das Steuergerät austauscht,wie lernt ihr das an?Hast Du den PIN der Wegfahrsperre?

Apart from that, I can't think of many reasons for a sudden failure of the engine control unit - after all, the engine was hardly replaced with the ignition on.