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Discussion Starter #1
I bought this car a few months back with 95K miles on it. I owned a 2005 Golf TDI previously and wanted to get my wife a good diesel for the mileage . After driving it for a couple of months she was complaining of drastically losing power while driving, what I later discovered to be "limp" mode. I also noticed that the car was extremely sluggish off the line, even worse when cold, but that much I expect.

In any case, we took it back to the dealer we bought the car from as they owed us some repairs, including replacing the AC compressor. Initially there was a code in the computer. I'm assuming an overboost and they replaced the boost valve. That had no effect on it, and we were still going into limp mode, although no codes were being reported anymore.

While they replaced the AC condenser, we had them go ahead and replace the timing belt, since it was due to be serviced soon anyway and they investigated the cam. Of course, they said there was wear on it, so we replaced that with the new and improved cam. The car does run smoother since, so I'll buy that.

Next they found a bent impeller on the turbo, assuming this was putting the car into limp mode, they sent the turbo out for a rebuild. The rebuild shop indicated the turbo had been oil-starved, so they next found a plugged oil return line and replaced.

All that appears to have fixed the limp mode issue, but the engine still doesn't make any power under 2000 rpm. This had the mechanic stumped so he farmed it out to another TDI expert, who felt the rebuilt Turbo was bad, so they put on a brand new Turbo. Still no power under 2K.

I'm out of money at this point to continue having them run around in circles. The car is drivable as long as the rpm's stay above 2k, you just have to time getting rolling.

I have read that this could be related to vacuum pressure or an MAF sensor (1.9 TDI) but don't know if the latter would be the case with the B5.

Any pointers/help would be much appreciated so that when I have some money again and a good recommendation for a mechanic in the Seattle area I can get this fixed. I can do a lot myself, but don't have the proper test tools to verify things.

Mech said there weren't any codes, I have since acquired vag-com and I'm including auto-scan output. It looks to me like I have a bad MAF sensor, but I'd like opinions/confirmation on anything else before I replace that.

Tuesday,02,August,2011,16:37:14:25120
VCDS Version: Release 10.6.4
Data version: 20110418



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Chassis Type: 3B - VW Passat B5
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


VIN: WVWCE63BX5E114242 Mileage: 157400km/97803miles
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Address 01: Engine Labels: 038-906-016-BHW.lbl
Part No SW: 038 906 016 R HW: 028 101 198 2
Component: R4 2,0L EDC G000AG 6416
Revision: 12345678 Serial number: VWZ7Z0D1096103
Coding: 0150034
Shop #: WSC 05311 000 00000
VCID: 234B13E19B45

2 Faults Found:
16486 - Mass Air Flow Sensor (G70): Signal too Low
P0102 - 000 - -
Freeze Frame:
RPM: 924 /min
Torque: 58.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Duty Cycle: 100.6 %
Bin. Bits: 00001000
Mass Air / Rev.: 355.0 mg/str
Mass Air / Rev.: 0.0 mg/str

16683 - Boost Pressure Regulation: Control Range Not Reached
P0299 - 000 - -
Freeze Frame:
RPM: 2394 /min
Torque: 238.0 Nm
Speed: 92.0 km/h
Load: 54.5 %
Voltage: 13.91 V
Bin. Bits: 00001000
Absolute Pres.: 2254.2 mbar
Absolute Pres.: 1815.6 mbar

Readiness: 0 0 0 0 0

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Address 02: Auto Trans Labels: 01V-927-156.lbl
Part No: 3B0 927 156 CF
Component: AG5 01V 2.0lPD USA 0505
Coding: 0001104
Shop #: WSC 05311 000 00000
VCID: 6CD938DD361B

No fault code found.

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Address 03: ABS Brakes Labels: 4B0-614-517.lbl
Part No: 4B0 614 517 G
Component: ABS/ESP front 3428
Coding: 04257
Shop #: WSC 05311
VCID: 254F0DF99571

No fault code found.

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Address 15: Airbags Labels: 6Q0-909-605-VW5.lbl
Part No: 1C0 909 605 C
Component: 09 AIRBAG VW61 04 0003
Coding: 12345
Shop #: WSC 05311
VCID: 244910FD9E4B

1 Fault Found:
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent

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Address 17: Instruments Labels: 3B0-920-xx5-17.lbl
Part No: 3B0 920 929 C
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 15235
Shop #: WSC 00000
VCID: 275307F1EF7D
WVWCE63BX5E114242 VWZ7Z0D1096103

1 Fault Found:
00779 - Outside Air Temp Sensor (G17)
30-10 - Open or Short to Plus - Intermittent

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Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 05311
VCID: F0E1ACAD9A33

No fault code found.

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Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 80 Komfortger·t HLO 0004
Coding: 00258
Shop #: WSC 05311
VCID: 3773D7B13FDD

Part No: 1C1959801
Component: 80 Tırsteuer.FS KLO 0202

Part No: 1C1959802
Component: 80 Tırsteuer.BF KLO 0202

Part No: 1C0959811
Component: 80 Tırsteuer.HL KLO 0202

Part No: 1C0959812
Component: 80 Tırsteuer.HR KLO 0202

No fault code found.

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Address 56: Radio Labels: 3B7-035-1xx-56.lbl
Part No: 3B7 035 180 G
Component: Radio PM6 0016
Coding: 00031
Shop #: WSC 05311
VCID: 244910FD9E4B

No fault code found.

End ---------------------------------------------------------------------
 

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The outside air temp sensor short is nothing, clear it and see if it comes back, if you want to fix it, trace the wirng.

It's possible the MAF is bad, since you already have vcds, do some datalogging while driving and compare the values shown to the requested value. If far off, something is causing that, either bad MAF, air restriction or bad EGR (displaces intake air). The low boost is also a problem. Many possible causes, check out the limp mode article. Although the article is written for the ALH, the procedures are the same on your BHW engine.

The only possible difference is that your turbo actuator may be a different psi, i've never tried testing mine. Test yours and then I'll test mine to see if it's much different. The actuator also has a sensor that can see vane position. That is the black thing on the end of it.

Also check camshaft torsion, see the FAQ for how to do this. If it's way off it should throw a code since the cam sensor will detect it but you never know what funny things can cause power issues so it's worth checking.

It shouldn't be a fuel delivery restriction since these normally show up at higher requested power too. Finally, check out the b5 new owner guide for some other common problems. I suggest doing the balance shaft replacement if you plan on keeping the car for a long time. If you're fed up with it, the 2012 Passat looks really good and priced right!
 

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Discussion Starter #3
Replaced MAF

Attached is a log of the Grp 3, 10, 11 taken after I changed out the MAF. The car is still a bit slow off the line, but it idles smoother and rolls through the rpms better. Let me know if anything stands out or if there is another group I should monitor.
 

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Discussion Starter #4
Still going into limp mode

Went into limp mode again as my wife was driving to work. Coded again with the following

Address 01: Engine Labels: 038-906-016-BHW.lbl
Part No SW: 038 906 016 R HW: 028 101 198 2
Component: R4 2,0L EDC G000AG 6416
Revision: 12345678 Serial number: VWZ7Z0D1096103
Coding: 0150034
Shop #: WSC 05311 000 00000
VCID: 234B13E19B45

1 Fault Found:
16683 - Boost Pressure Regulation: Control Range Not Reached
P0299 - 000 - - - Intermittent
Freeze Frame:
RPM: 2289 /min
Torque: 192.0 Nm
Speed: 62.0 km/h
Load: 43.9 %
Voltage: 14.21 V
Bin. Bits: 00001000
Absolute Pres.: 2080.8 mbar
Absolute Pres.: 1570.8 mbar

Readiness: 1 1 0 0 0
 

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Boost looks a little off but it's hard to see because it's not in graph form.

You've replaced the turbo, N75 boost solenoid, and MAF. At least some more expensive things have been checked. What else, have all vac lines been checked? Boost leak test done? Start working through the limp mode article.
 

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passat limp mode

I have an 04 Passat that keeps going into limp mode since I had a head, injectors and turbo replaced.
I had the car dyno'd on original tune 105hp, Kermatune 125hp. It threw no codes on the dyno under load. Next day just cruising on highway under slight load -limp. N75 replaced, nothing changed. Ideas?
 

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Looks like the wastegate is not fully closing at low rpm,could it be that the stop screw has been moved perhaps?since they worked on that turbo or improperly adjusted actuator?
 
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