Turbo, injector and Under boost faults

[JimmyG1980]

Been having problems with my 2007 BKP 133k Passat B6 Estate.
Bit of background, had it since early 2018, oil pump went end of 2022 but managed to pull over straight away so didn't cause any damage to the engine.
Started in January when it died on the way to work, loads of white smoke out of the back and noisy engine.

Here is the scan that was pulled straight after...

Saturday,13,January,2024,10:43:57:00009VCDS -- Windows Based VAG/VAS Emulator Running on Windows 11 x64
VCDS Version: 23.3.1.0
Data version: 20230421 DS346.2
www.Ross-Tech.com




VIN: WVWZZZ3CZ8E101761   License Plate: WG57 KBJ
Mileage: 215160km-133694mi   Repair Order: 






--------------------------------------------------------------------------------
--------------------------------------------------------------------------------




Chassis Type: 3C (3C0)
Scan: 01 03 08 09 15 16 17 19 22 25 36 42 44 46 52 53 56 62 72


VIN: WVWZZZ3CZ8E101761   Mileage: 215160km-133694miles


01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: Malfunction 0010
09-Cent. Elect. -- Status: Malfunction 0010
15-Airbags -- Status: Malfunction 0010
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
22-AWD -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
36-Seat Mem. Drvr -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: Malfunction 0010
52-Door Elect, Pass. -- Status: Malfunction 0010
53-Parking Brake -- Status: Malfunction 0010
56-Radio -- Status: OK 0000
62-Door, Rear Left -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
 
-------------------------------------------------------------------------------
Address 01: Engine        Labels: 03G-906-018-BKP.clb
   Part No SW: 03G 906 018 FG    HW: 03G 906 018 FG
   Component: R4 2.0l PPD1.5      0907  
   Revision: --H45---    Serial number: VWZCZ000000000
   Coding: 0000172
   Shop #: WSC 05314 000 00000
   VCID: 6FED66BB7E9D05EB22-803A
   VINID: 9E69EAAAA0D3A885410011C60450DBC9B9


4 Faults Found:
004705 - PD Unit Injector: Cylinder 1 (N240) 
               P1261 - 006 - Regulation Range Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100001
                    Fault Priority: 0
                    Fault Frequency: 14
                    Reset counter: 37
                    Mileage: 214970 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 11:47:39


             Freeze Frame:
                    RPM: 1568 /min
                    Torque: 104.0 Nm
                    Speed: 0.0 km/h
                        86.97 %
                    Text:  4.125    uF            
                    Text: 11.75    mJ             
                    Text:      3    mJ            
                    Raw, Form. N/A: 000 000 000


004711 - PD Unit Injector: Cylinder 3 (N242) 
               P1267 - 006 - Regulation Range Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100001
                    Fault Priority: 0
                    Fault Frequency: 10
                    Reset counter: 36
                    Mileage: 214972 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 11:49:58


             Freeze Frame:
                    RPM: 1536 /min
                    Torque: 120.0 Nm
                    Speed: 43.0 km/h
                        81.51 %
                    Text:  4.875    uF            
                    Text: 14.25    mJ             
                    Text:     10    mJ            
                    Raw, Form. N/A: 000 000 000


004720 - PD Unit Injector: Cylinder 4 (N243) 
               P1270 - 006 - Regulation Range Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100001
                    Fault Priority: 0
                    Fault Frequency: 5
                    Reset counter: 32
                    Mileage: 215004 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 07:58:47


             Freeze Frame:
                    RPM: 1408 /min
                    Torque: 96.0 Nm
                    Speed: 62.0 km/h
                        81.90 %
                    Text:  4.875    uF            
                    Text: 14.50    mJ             
                    Text:      7    mJ            
                    Raw, Form. N/A: 000 000 000


000665 - Boost Pressure Regulation 
               P0299 - 006 - Control Range Not Reached - Intermittent
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 40
                    Mileage: 215161 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 09:51:47


             Freeze Frame:
                    RPM: 3008 /min
                    Torque: 160.0 Nm
                    Speed: 44.0 km/h
                        64.74 %
                    Voltage: 14.46 V
                    Pressure: 1874.4 mbar
                    Pressure: 639.0 mbar


Readiness: N/A


-------------------------------------------------------------------------------
Address 03: ABS Brakes        Labels:. 3C0-614-109-C4.clb
   Part No SW: 3C0 614 109 D    HW: 3C0 614 109 D
   Component: J104    C4 440 V2   0003  
   Revision: --020---    Serial number: 00000776299934
   Coding: 0001297
   Shop #: WSC 05311 000 00000
   VCID: 1F4D567BCEBDD56BD2-804A


No fault code found.


-------------------------------------------------------------------------------
Address 08: Auto HVAC        Labels: 3C0-907-044.clb
   Part No SW: 3C0 907 044 CB    HW: 3C0 907 044 CB
   Component: ClimatronicPQ46 122 0707  
   Revision: 00122021    Serial number: 00000000000000
   Shop #: WSC 00000 000 00000
   VCID: 63C51A8BA255B18BB6-8036


1 Fault Found:
01592 - Air Quality Sensor (G238) 
            014 - Defective
             Freeze Frame:
                    Fault Status: 01101110
                    Fault Priority: 3
                    Fault Frequency: 254
                    Reset counter: 236
                    Mileage: 212603 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 11:06:30




-------------------------------------------------------------------------------
Address 09: Cent. Elect.        Labels:. 3C0-937-049-30-H.lbl
   Part No SW: 3C0 937 049 AJ    HW: 3C0 937 049 AJ
   Component: Bordnetz-SG     H54 2202  
   Revision: 00H54000    Serial number: 01000007680584
   Coding: E1888F0700041A00470A00000F00000000085D435C000100000000000000
   Shop #: WSC 05124 000 00000
   VCID: 71E960C368A9131B34-8024


   Subsystem 1 - Part No: 3C2 955 119 B  Labels: 1KX-955-119.CLB
   Component: Wischer 270907 022  0601  
   Coding: 00046997
   Shop #: WSC 05124  


   Subsystem 2 - Part No: 1K0 955 559 AF  Labels: 1K0-955-559-AF.CLB
   Component: RLS     121007 046  0204  
   Coding: 00208933
   Shop #: WSC 05124  


3 Faults Found:
00987 - Lamp for Brake Light; Left (M9) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 1
                    Fault Frequency: 46
                    Reset counter: 14
                    Mileage: 213128 km
                    Time Indication: 0
                    Date: 2005.09.13
                    Time: 31:63:63


             Freeze Frame:
                        ON
                    Voltage: 11.45 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


02395 - Parking Light Front Right (M3) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 2
                    Fault Frequency: 36
                    Reset counter: 21
                    Mileage: 214085 km
                    Time Indication: 0
                    Date: 2005.09.13
                    Time: 31:63:63


             Freeze Frame:
                        ON
                    Voltage: 14.05 V
                        ON
                        ON
                        OFF
                        OFF
                        OFF


00985 - Right Tail Light (M2) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00111100
                    Fault Priority: 2
                    Fault Frequency: 2
                    Reset counter: 5
                    Mileage: 214654 km
                    Time Indication: 0
                    Date: 2005.09.13
                    Time: 31:63:63


             Freeze Frame:
                        ON
                    Voltage: 14.00 V
                        ON
                        ON
                        OFF
                        OFF
                        ON




-------------------------------------------------------------------------------
Address 15: Airbags        Labels: 3C0-909-605.lbl
   Part No SW: 3C0 909 605 M    HW: 3C0 909 605 M
   Component: 0C AIRBAG VW8   032 2522  
   Revision: 12032000    Serial number: 003B1PLMFS30  
   Coding: 0012355
   Shop #: WSC 05311 000 00000
   VCID: 306FA5C7A3235A137B-8064


   Subsystem 1 - Serial number: 6332MSME176B341E 


   Subsystem 2 - Serial number: 6342MSME172C7715 


   Subsystem 3 - Serial number: 6351HTS6L4ICA337 


   Subsystem 4 - Serial number: 6361HTS6OFJCD556 


   Subsystem 5 - Serial number: 00000000000000000


   Subsystem 6 - Serial number: 00000000000000000


1 Fault Found:
01578 - Airbag Deactivation Warning Lamp; Passenger Side (K145) 
            009 - Open or Short to Ground - MIL ON


-------------------------------------------------------------------------------
Address 16: Steering wheel        Labels: 3C0-953-549-SW20.lbl
   Part No SW: 3C0 953 549 J    HW: 3C0 953 549 J
   Component: Lenks ulenmodul 006 0010  
   Revision: 00006000    Serial number: 3C9953507BC   
   Coding: 0000004
   Shop #: WSC 05311 000 00000
   VCID: 3365AACB5235610B06-8066


No fault code found.


-------------------------------------------------------------------------------
Address 17: Instruments        Labels: 3C0-920-xxx-17.lbl
   Part No SW: 3C0 920 960 N    HW: 3C0 920 960 N
   Component: KOMBIINSTRUMENT VD1 1216  
   Revision: V0002000    Serial number: 00000000000000
   Coding: 0007405
   Shop #: WSC 12345 067 57207
   VCID: 2E53BBBFB9174CE369-807A


No fault code found.


-------------------------------------------------------------------------------
Address 19: CAN Gateway        Labels:. 3C0-907-530-V2.clb
   Part No SW: 3C0 907 530 E    HW: 3C0 907 951 
   Component: J533__Gateway   H10 0080  
   Revision:   H10       Serial number: 1200P07A1702B5
   Coding: F982FF060002022003
   Shop #: WSC 05311 000 00000
   VCID: 23455A8BE2D5F18BF6-8076


No fault code found.


-------------------------------------------------------------------------------
Address 22: AWD        Labels: 1K0-907-554.lbl
   Part No: 1K0 907 554 K
   Component: Haldex 4Motion      1118  
   Coding: 0000001
   Shop #: WSC 00000 000 00000
   VCID: 356194D35C417F3B28-8060


No fault code found.


-------------------------------------------------------------------------------
Address 25: Immobilizer        Labels: 3C0-959-433-25.clb
   Part No SW: 3C0 959 433 R    HW: 3C0 959 433 R
   Component:    IMMO         042 0383  
   Revision: 00042000    Serial number: VWZCZ000000000
   Shop #: WSC 131071 1023 2097151
   VCID: 397998E370599B5BCC-806C


   Subsystem 1 - Part No: 3C0 905 861 G
   Component:    ELV          027 0380
   3C0905861G     ELV          027 0380   


No fault code found.


-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr        Labels: 3C0-959-760.lbl
   Part No SW: 3C0 959 760 E    HW: 3C0 959 760 E
   Component: Sitzverstellung     1101  
   Revision: 00005000    Serial number: 00000000000000
   Shop #: WSC 00000 000 00000
   VCID: 2F6DA6BBBE1D45EB62-807A


No fault code found.


-------------------------------------------------------------------------------
Address 42: Door Elect, Driver        Labels:. 1K0-959-701-MAX3.clb
   Part No SW: 1K0 959 701 Q    HW: 1K0 959 793 M
   Component: J386  TUER-SG FT    1132  
   Revision: 31008001    Serial number: 00000048778922
   Coding: 0000951
   Shop #: WSC 05311 000 00000
   VCID: 3C7781F77F6BAE73D7-8068


No fault code found.


-------------------------------------------------------------------------------
Address 44: Steering Assist        Labels: 1Kx-909-144-G2V3.clb
   Part No: 1K2 909 144 M
   Component: EPS_ZFLS Kl.136 H08 1901  
   Shop #: WSC 02069 000 90108
   VCID: 366393DF4147742321-8062


No fault code found.


-------------------------------------------------------------------------------
Address 46: Central Conv.        Labels:. 3C0-959-433-46.clb
   Part No SW: 3C0 959 433 R    HW: 3C0 959 433 R
   Component:    KSG PQ46 ELV 042 0472  
   Revision: 00042000    Serial number: VWZCZ000000000
   Coding: 0191020051030E76300494157008DFCE107CA0
   Shop #: WSC 05311 000 00000
   VCID: 397998E370599B5BCC-806C


   Subsystem 1 - Part No: 1K0 951 605 D
   Component: LIN BACKUP HORN H07 9001


   Subsystem 2 - Part No: 3C0 951 171 C
   Component: Neigungssensor  004 0611


   Subsystem 3 - Part No: 3C0 951 171 C
   Component: Innenraumueberw.004 0611


1 Fault Found:
01038 - Central Locking Thermal Protection 
            000 - - - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 4
                    Fault Frequency: 254
                    Reset counter: 19
                    Mileage: 212678 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 15:08:16




-------------------------------------------------------------------------------
Address 52: Door Elect, Pass.        Labels:. 1K0-959-702-MAX3.clb
   Part No SW: 1K0 959 702 Q    HW: 1K0 959 792 M
   Component: J387  TUER-SG BT    1132  
   Revision: 31008001    Serial number: 00000500078809
   Coding: 0000950
   Shop #: WSC 05311 000 00000
   VCID: 3D718CF36471A77BE0-8068


1 Fault Found:
00940 - Mirror Adjust Motor; Passenger Side (V150) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 4
                    Fault Frequency: 48
                    Reset counter: 7
                    Mileage: 212633 km
                    Time Indication: 0




-------------------------------------------------------------------------------
Address 53: Parking Brake        Labels: 5N0-907-801.clb
   Part No SW: 3C0 907 801 J    HW: 3C0 907 801 J
   Component: J540 EPB3  VW-09393 0009  
   Revision:   008       Serial number: 00000000209610
   Coding: 0000057
   Shop #: WSC 05311 000 00000
   VCID: 295948A380F92BDBBC-807C


5 Faults Found:
03200 - Switch for Electric Parking Brake (E538) 
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00111100
                    Fault Priority: 1
                    Fault Frequency: 5
                    Reset counter: 252
                    Time Indication: 0


             Freeze Frame:
                    Voltage: 12.40 V
                    Count: 10
                         -
                    Hex Value: 0x0171
                    Hex Value: 0x0082
                    Hex Value: 0x1001


02432 - Supply Voltage for Left Parking Brake Motor (V282) 
            011 - Open Circuit - MIL ON
             Freeze Frame:
                    Fault Status: 11101011
                    Fault Priority: 2
                    Fault Frequency: 102
                    Reset counter: 236
                    Mileage: 214909 km
                    Time Indication: 0


             Freeze Frame:
                    Voltage: 14.00 V
                    Count: 30
                    Speed: 0.0 km/h
                    Hex Value: 0x1271
                    Hex Value: 0x0001
                    Hex Value: 0x1002


00446 - Function Limitation due to Under-Voltage 
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 1
                    Fault Frequency: 8
                    Reset counter: 253
                    Mileage: 214909 km
                    Time Indication: 0


             Freeze Frame:
                    Voltage: 11.60 V
                    Count: 52
                    Speed: 0.0 km/h
                    Hex Value: 0x12F1
                    Hex Value: 0x0001
                    Hex Value: 0x1010


02845 - Function Display in Instrument Cluster (!) 
            007 - Short to Ground - MIL ON
             Freeze Frame:
                    Fault Status: 11100111
                    Fault Priority: 2
                    Fault Frequency: 254
                    Reset counter: 236
                    Mileage: 212603 km
                    Time Indication: 0


             Freeze Frame:
                    Voltage: 11.90 V
                    Count: 78
                    Speed: 0.0 km/h
                    Hex Value: 0x1260
                    Hex Value: 0x0001
                    Hex Value: 0x0101


02442 - Function Lamp in Control Head 
            009 - Open or Short to Ground - Intermittent
             Freeze Frame:
                    Fault Status: 00101001
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 252
                    Time Indication: 0


             Freeze Frame:
                    Voltage: 11.80 V
                    Count: 81
                    Speed: 0.0 km/h
                    Hex Value: 0x0871
                    Hex Value: 0x0008
                    Hex Value: 0x1001

Pulled over straight away and got it towed to my mechanic, turbo had got so got a re-conditioned one and had it replaced.

Afterwards I was still getting the PD Unit Injector: Regulation Range Exceeded - Intermittent fault on cylinders 1, 3 and 4.
Along with the boost pressure regulation fault intermittently, mainly when driving up hill in low gears. Small amount of smoke out of exhaust.
My mechanic checked the wiring from the ECU to the injectors, replaced seals on injectors and replaced injector wiring loom.
Fuel filter was dirty so that was cleaned out and replaced.
Still the same issues, he then switched injectors 2 and 3 over and the fault moved to cylinder 2.

Probably should have given up here but decided to keep going.

Bought 4 re-manufactured injectors, which were installed.
Now only had the Injector fault on cylinder 2, and the intermittent boost fault.
We figured the one of the injectors must have been faulty so we replaced it with the one of the original 4 which was not throwing up the fault code.

Now after quite a few drives we have no injector faults at all and definitely more power than before. Sounds good on idle and when coasting but quite lumpy/juddery engine when accelerating. Kicks in at around 1500rpm.

The only fault I am getting now is...

000665 - Boost Pressure Regulation 
               P0299 - 006 - Control Range Not Reached - Intermittent
             Freeze Frame:
                    Fault Status: 00000001
                    Fault Priority: 5
                    Fault Frequency: 1
                    Reset counter: 40
                    Mileage: 216356 km
                    Time Indication: 0
                    Date: 2000.00.00
                    Time: 15:56:08


             Freeze Frame:
                    RPM: 2432 /min
                    Torque: 184.0 Nm
                    Speed: 56.0 km/h
                        99.45 %
                    Voltage: 14.35 V
                    Pressure: 2343.0 mbar
                    Pressure: 1128.9 mbar

Does anyone have any ideas what could be causing this?
Seems like other on the forum with this issue have vacuum leaks or swirl flap/inlet manifold issues.

[Crasher]

Underboost is nearly always a leak in the vacuum system.

[JimmyG1980]

Thanks for the quick reply, do you think that would cause the rough running?
Now that I am not getting any codes for the injectors can I rule them out?

Also were would be the best place to start looking for vacuum leak?

[Crasher]

It won’t cause poor running like on a petrol engine, BKP injectors are notorious for running problems even without code, study the balances and anything approaching +/-1 is a problem.