Lambda P2196 - 000 - Signal too High (Rich) and

[s1paulj]

Hi all,
All help gratefully received.
2008 Passat 2.0 140HP common rail diesel, I believe a CBA engine on about 130K miles.

My tale of woe started 2 weeks ago when the engine fault light indicated a problem. So I finally bit the bullet and purchased a VCDS unit. First fault log below.
After a bit of forum research, I ordered and fitted a new VDO throttle body. I cleaned the EGR while it was off.
Disassembling the old throttle body out of curiosity I found the gear box and motor of the unit full of thick black oil, presumably leaking through the butterfly bearing over time. So not surprised it was faulty.
Fitting the new throttle body seems to have cured the P2102 signal low fault as that has not happened since.

But the car is now showing the second faults below - Still have the lambda fault but now also have: 000665 - Boost Pressure Regulation P0299 - 000 - Control Range Not Reached

After fitting the new throttle body the car was OK for about 500 miles then showed the fault and went into limp mode. Stopping and re-starting it runs fine for a while. But now after tinkering some (Cleaning the lambda sensor and I replaced the gasket between the exhaust gas return pipe and the EGR as i re-used the old one) to try and fix the errors, it seems to run OK for a mile or so then shows the fault and goes into limp mode.
Questions:
Could the two current faults - Lambda sensor and Boost pressure be connected?? The Lambda fault seems to have been there since May
I've had the lambda sensor pickling in vinegar for 24 hours to try and clean it, but its made no difference - should i just replace it??
Any ideas what could be causing the Boost pressure problem - could it be something to do with changing the throttle body?
I found a post about calibrating the throttle body, but the block numbers for VCDS given in the post didn't work so i haven't done that - does it need calibrating?

Many thanks in advance

Regards
Paul
First set of faults
Address 01: Engine (CBA) Labels: 03L-906-022-CBA.clb
Part No SW: 03L 906 022 FN HW: 03L 907 309
Component: R4 2,0L EDC G000SG 2643
Revision: --H01--- Serial number: VWZCZ000000000
Coding: 0000072
Shop #: WSC 84224 802 739910
VCID: 76B6EFF824C052D7075-8022


5 Faults Found:
008598 - Oxygen (Lambda) Sensor B1 S1
P2196 - 000 - Signal too High (Rich) - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 2
Fault Frequency: 92
Reset counter: 255
Mileage: 203622 km
Time Indication: 0
Date: 2017.05.11
Time: 06:50:46


Freeze Frame:
RPM: 2001 /min
Speed: 70.0 km/h
Lambda: 53.7 %
Mass Air / Rev.: 535.0 mg/str
(no units): 23.71
(no units): 16.0
Voltage: 0.975 V


008450 - Throttle Valve Actuator Module (J338): Motor Circuit
Motor Circuit
P2102 - 000 - Signal Low - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 19
Reset counter: 255
Mileage: 208375 km
Time Indication: 0
Date: 2017.07.13
Time: 20:02:18


Freeze Frame:
RPM: 1794 /min
Speed: 77.0 km/h
Load: 25.5 %
Load: 15.3 %
Lambda: 100.2 %
Mass Air / Rev.: 670.0 mg/str
Temperature: 89.1°C

Second set of faults:
008598 - Oxygen (Lambda) Sensor B1 S1
P2196 - 000 - Signal too High (Rich)
Freeze Frame:
Fault Status: 01100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 210047 km
Time Indication: 0
Date: 2017.08.06
Time: 15:38:40


Freeze Frame:
RPM: 1357 /min
Speed: 47.0 km/h
Lambda: 42.6 %
Mass Air / Rev.: 470.0 mg/str
(no units): 25.40
(no units): 16.0
Voltage: 0.975 V


000665 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
Fault Status: 01100000
Fault Priority: 2
Fault Frequency: 1
Reset counter: 255
Mileage: 210049 km
Time Indication: 0
Date: 2017.08.06
Time: 15:40:28


Freeze Frame:
RPM: 2277 /min
Speed: 98.0 km/h
Absolute Pres.: 2346.0 mbar
Absolute Pres.: 1224.0 mbar
Temperature: 28.8°C
Mass Air / Rev.: 545.0 mg/str
Lambda: 12.6 %




Readiness: 0 0 0 0 0
Sunday,06,August,2017,17:08:54:30454
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 17.8.0.1 (x64) HEX-V2 CB: 0.4401.4
Data version: 20170721 DS276.2
Ross-Tech: Home

[philipharmes]

Hi Paul, my son's Passat, same year & engine as yours had the same original fault a few years ago.
The throttle valve was full of oil just like your one.
I replaced it & it totally cured the problem, no setting up required with the new valve.

I have a Passat estate, same year & engine & have had the same Lambda fault, I tried cleaning but no success.
It caused no detectable loss of power or drivability while faulty, I replaced it with a second hand unit from a breakers & had no further problems.

So the problem you have been left with seems a bit unusual.
It sounds like the turbo isn't boosting enough or some pressure is being lost.
Maybee you have a leak somewhere in the pipework from turbo to intercooler to inlet, sometimes hard to find as very low bost pressure when the car is at a standstill.

The other thing that springs to mind is that when the throttle valve fails it stops the DPF from regenerating.
If that gets blocked it will reduce exhaust flow, so low boost from the turbo.
It should have regenerated itself by now but you could try a forced regen now you have VCDS.

Hope the above might throw some light on your problem.

[s1paulj]

Thanks for the input Philip. Looks like 3 separate faults then, although I still can't help thinking the boost pressure has something to do with me changing the throttle valve. Not a big believer in coincidence!
Cheers
Will replace the Lambda sensor, at least i hope i can clear another fault...

[DMitch16]

It's a diesel and does not have a throttle valve. The unit you are talking about is the antishudder flap unit. It opens under motor power when the engine is started. It slams shut under spring pressure when the engine is shut off to prevent further intake thus eliminating shake / shudder caused by engine overrun.

The P0299 is indicative of a vacuum leak, failed N75 solenoid valve or failed turbo actuator diaphragm or sticking turbo VNT mechanism causing under / over boost and limp mode. Might be coincidental to the antishudder flap issue. Some engines also have a motor driven or vacuum actuated flap unit inside the intake manifold (swirl flaps). This motor on the electrical actuated version is also prone to failure as it has plastic gearing which often wears out or breaks not to mention issues with the flap mechanism itself. Codes however usually refer to the V157 motor (even when it has a vacuum actuation method!) or Inlet Manifold Runner control deviation.

I see from your other thread that it was the actuator diaphragm so no need for further comments.