BKP problem ** Advice Needed**

[anthonyf5]

Hi all, so I recently bought a 2006 Passat with the 2.0 BKP engine.

The car has had an ongoing issue since before purchase.

The car drives very well and is no way hesitant throughout the rev range, the issue only arises when it is sitting ticking over.

It seems to idle at at a very low RPM (almost like it finds a low idle if that makes sense?) and when it does this, it causes a shudder or a vibration of sorts.

The problem is not there 100% of the time, but it certainly is there MOST of the time


It is visibly noticeable in the engine bay when this is happening, the engine shakes excessively particularly around the upper left mount / alternator area ( as you look into the bay)

A small blip of throttle and the shudder will go away for around five to ten seconds and then proceed to return.

I have checked the alternator clutch pulley and it seems fine. I think I can rule out the DMF as clutching does not lessen or remove the shudder.

Also, there are no warning lights etc showing on the dash.
!
I would really appreciate some guidance as I'm stumped!!

[DMitch16]

Hi all, so I recently bought a 2006 Passat with the 2.0 BKP engine.

The car has had an ongoing issue since before purchase.

The car drives very well and is no way hesitant throughout the rev range, the issue only arises when it is sitting ticking over.

It seems to idle at at a very low RPM (almost like it finds a low idle if that makes sense?) and when it does this, it causes a shudder or a vibration of sorts.

The problem is not there 100% of the time, but it certainly is there MOST of the time


It is visibly noticeable in the engine bay when this is happening, the engine shakes excessively particularly around the upper left mount / alternator area ( as you look into the bay)

A small blip of throttle and the shudder will go away for around five to ten seconds and then proceed to return.

I have checked the alternator clutch pulley and it seems fine. I think I can rule out the DMF as clutching does not lessen or remove the shudder.

Also, there are no warning lights etc showing on the dash.
!
I would really appreciate some guidance as I'm stumped!!

Ah the infamous B6 2.0 litre lumpy idle!

There's a few things that could cause the vibration...

Dirty / partially blocked injector.
DMF wobble.
Fuel contamination.
Timing not adjusted to optimum level.
Injector piston clearance excessive.
Bad engine mount.
More serious engine wear

My idle is 750 hot, 800 at spring summer start up and 900 in very cold weather for a few minutes.

Live data from a VCDS scan would help as you'll be able to look at idle stabilisation, health of injectors and other useful readings.

[Crasher]

Get a fault code read done, if nothing shows get them to check the injector balances. Open up the fuel filter and see if the fuel inside is black.

[Gazwould]

Also throttle body - plastic cogs .

[DMitch16]

Also throttle body - plastic cogs .

And...say it Gaz...starts with '77' :biglaugh::biglaugh::biglaugh:

[Gazwould]

Yep , 77 toothed cog breaks but 100 tooth doesn't .

[DMitch16]

Anthonyf5 - what is your current mileage on the car?

[anthonyf5]

Anthonyf5 - what is your current mileage on the car?

173,000 and going strong(ish) :o

thanks for the replies and guidance chaps it's much appreciated.


unfortunately I don't have access to VCDS, I can get the car checked locally this week but I think the guy uses a generic system and for the life of me I cannot remember the name.

Would it be worth taking the rocker off to inspect the Injector loom, also , how problematic are the EGR's?

This is my first B6 , had many a care free years in B5.5's so am relatively unfamiliar with these

[Gazwould]

Quite a big difference in reliability terms .

[anthonyf5]

Quite a big difference in reliability terms .

Night and day . But I'm only basing that on having owned this one B6, probably not a fair assessment. Had I went for one a few years younger I'd say it would be less problematic.

Oh and I believe it's Delphi diagnostic software the guy is using?

[anthonyf5]

Get a fault code read done, if nothing shows get them to check the injector balances. Open up the fuel filter and see if the fuel inside is black.

just got diagnostics done, injector 1 was showing a fault, he checked the loom-injector plug and it's perfect so he said the injector needs replacing.

relieved in a way as I now know what the issue is and how to fix it, he also said the engine seemed to be in top nick, injector aside.

My question now is what route should I go down in terms of buying a replacement? I don't know if I can justify buying a new one on a sub €1000 car, or are they even expensive?

Just rang a local breaker and he said he has one for €80, is this about right?

oh and does it specifically have to be an injector from a Passat BKP engine or are there variations that work, from a golf for example.??

I'm going to be selling the car on once it's sorted

[DMitch16]

Brand new would be between £125 and £460 plus VAT each.
£125 for a BKD 'B' revision, £300 for a BKD later 'G' revision and £460 plus VAT for a Siemens 'S' revision (most likely to fit).

Used anywhere from around £50 upwards depending on condition but they do seem to be engine specific. Yours would be 03G 130 073 S for a BKP compatible injector.

From VW they are over £800 each!

[anthonyf5]

Picked up one from a breakers yesterday. It's a Siemens and I guess it's impossible to know what condition it's in until fitted. Shot in the dark I guess.....

03G 130 073 D??? please don't tell me that this is an early fault prone injector?!

[Crasher]

It MUST be set up for stroke.

[anthonyf5]

It MUST be set up for stroke.

sorry but I'm lost, do you mean using a dial indicator or how is that done?

[Crasher]

Yes, you set up the injector maximum stroke, each one can vary quite considerably.

http://i222.photobucket.com/albums/dd20/Crasher1964/PD16vinjectorlift.jpg (http://s222.photobucket.com/user/Crasher1964/media/PD16vinjectorlift.jpg.html)

http://i222.photobucket.com/albums/dd20/Crasher1964/PDinjectrorsetangle.jpg (http://s222.photobucket.com/user/Crasher1964/media/PDinjectrorsetangle.jpg.html)f

[DieselMonster]

Crasher is talking about setting up the injector lash. Read about it online and see you tube vid tutorials. Some use dials, others use their bare eyes.

[Crasher]

I would describe it as pre load rather than lash, anyway lash is Yank speak, you are in England so it's "clearance" or "gap" ;)

[anthonyf5]

thanks Crasher all guidance is appreciated.

Unfortunately the new injcetor has not fixed the problem.

Car still has a misfire at idle and only at idle.

My way of thinking suggests that an injector loom issue would cause a constant misfire throughout the rev range, or is this not the case?!

[Crasher]

The looms are unreliable and should always be chnaged with the injector(s), when the injector recall was in operation the repair kit came with a new loom, many didn't get fitted but there were quite a few on eBay around that time, odd that isn't it! A faulty loom will leave an electrical circuit malfunction code.