[freshapple]

Hi all, my vacuum nipple came loose that is pressed into the housing of my vacuum pump so I replaced the unit on the side of the head of my ‘05 Passat B5.5. I spilled some fuel when swapping it out and air got in the line. It took a few cranks but it restarted.
Now, it sounds like I am only running on 3 cylinders and I hear a popping noise coming from the engine as if there is a mis-fire.

Any thoughts on how to correct it so it runs smoothly again?

 

[freshapple]

It finally threw a CEL and is in limp mode:

2 Faults Found:
16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
RPM: 2205 /min
Torque: 180.0 Nm
Speed: 39.0 km/h
Load: 43.5 %
Voltage: 14.29 V
Bin. Bits: 00101000
Absolute Pres.: 2040.0 mbar
Absolute Pres.: 1611.6 mbar

16485 - Mass Air Flow Sensor (G70)
P0101 - 000 - Implausible Signal
Freeze Frame:
RPM: 2100 /min
Torque: 0.0 Nm
Speed: 110.0 km/h
Temperature: 51.3°C
(no units): 19.2
(no units): 1.59
Temperature: 97.2°C

 

[freshapple]

and some other VCDS readings:

Group 13 - Idle Stabilization
Cyl 1: -3.01 mg/str (this one is way off!)
Cyl 2: 1.15 mg/str
Cyl 3: 0.72 mg/str
Cyl 4: 1.95 mg/str

Group 5: Start Conditions
Injection Quantity: 24.2 mg-str

Group 4: Injection Timing
Injection Start: 5.6 BTDC
Injection Duration 9.2 KW
Torsion Value: 1.0 KW

Group 3: Exhaust Gas Recirculation (EGR)
Mass Air Flow (specified): 475.0 mg/str
Mass Air Flow (actual) 380.0 mg/str
Duty Cycle: 100%

Group 1: Injection Quantity
Injection Quantity: 20.0 ,g/styr
Supply Duration: 8.2 KW
Coolant Temp (G62): 75.6 C

 

[freshapple]

I was looking up troubleshooting info and came across this video. He seems to be having a similar issue where one of the injectors is dropping out. Has anyone had experience with intermittent misfiring and these injector connectors on PD engines?

 

[freshapple]

So I went through and checked the fuel injector electrical plugs like in the video to see if they were loose... no difference. It still sounds rough, like it's running on 3 cylinders and making a lot of black smoke and soot. Cam and lifters were replaced at 181,909mi. Have 231,597mi now. Cam and lifters looked good when I had the rocker cover off to tighten up the electrical connectors on the injectors.

Thoughts anyone?
I can run more VCSD info if there's something else I should be looking at.

 

[freshapple]

So I ordered a new Pierburg Tandem Pump, Fuel Filter, and some Diesel Purge. Going to see if a new pump will deliver better pressure and then use the diesel purge to clean the injectors as best possible without removing them.

 

[freshapple]

I received the new tandem pump and installed it, then got it started and running on diesel. After getting it running, I ran some diesel purge through it with no improvement...
It's still running on 3 cylinders, misfiring, and thick black soot is coming out from the tailpipe and accumulating on the rear of the car.

Thoughts on what to tackle next...?