Could use some help troubleshooting possible turbo issue

I recently bought a 2005 Passat wagon 2.0 TDI for a really good price because it had a boost code
and the owner didn't want to pay the dealership their quoted price to get it fixed.

I would appreciate any advice on what to do to get this running and the best order of operations, story follows...


I was able to drive it home (in limp mode?) and the next day it wouldn't start. I ran the battery down
trying to start it (This is my first diesel and my first VW that isn't a beetle...I know better now).

I ordered a Vag-Com and a repair manual that I was assured included this model hoping that would be all I needed...
of course it doesn't cover this engine.

While I was waiting for the Vag-Com I did the following:
- Disconnected battery(attempting to reset the immobilizer) and charged the battery,

-Replaced the 219 relay as I have read that it is a common cause of the codes that I had from my OBD

-Visibly inspected all the hoses and vac lines,

-Pulled the MAF, it appears to be a new one to go with the brand new air filter,

-Put a mighty vac on the actuator and watched it push the rod down and back up a few times,
couldn't see it well enough to be able to note exact pressure.

-Pulled the intake air hose off the turbo(there was a couple drops worth of oil in there)
and spun the turbo with my finger(rotates but doesn't "spin" on it's own, should it?), checked for in-out play(none),

-Was able to start the car when the Vag-com came, reading are as follows:


VIN: WVWCE63B95E116080 License Plate:
Mileage: 326190km-202685mi Repair Order:



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


Chassis Type: 3B (3B - VW Passat B5 (1997 > 2005))
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


VIN: WVWCE63B95E116080 Mileage: 326190km/202685miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-016-BHW.lbl
Part No SW: 038 997 016 T HW: 028 101 198 2
Component: R4 2,0L EDC G000AG 0314
Revision: 12345678 Serial number: VWZ7Z0D1096047
Coding: 0150034
Shop #: WSC 23312 444 84483
VCID: 2F6DF537BDE897663D9-5072

4 Faults Found:
16485 - Mass Air Flow Sensor (G70)
P0101 - 000 - Implausible Signal
Freeze Frame:
RPM: 1470 /min
Torque: 0.0 Nm
Speed: 57.0 km/h
Temperature: 27.0°C
(no units): 25.2
(no units): 0.82
Temperature: 75.6°C

17978 - Engine Start Blocked by Immobilizer
P1570 - 000 - - Intermittent
Freeze Frame:
RPM: 924 /min
Torque: 34.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 11.40 V
Bin. Bits: 00001000
Bin. Bits: 11000000
(no units): 0.0

16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
RPM: 2394 /min
Torque: 240.0 Nm
Speed: 64.0 km/h
Load: 54.9 %
Voltage: 13.98 V
Bin. Bits: 00001000
Absolute Pres.: 2264.4 mbar
Absolute Pres.: 1764.6 mbar

17586 - Linear O2 Sensor; Pump Current
P1178 - 000 - Open Circuit
Freeze Frame:
RPM: 2520 /min
Torque: 120.0 Nm
Speed: 48.0 km/h
Load: 31.0 %
Mass Air / Rev.: 420.0 mg/str
(no units): 0.20
(no units): 8.0
Bin. Bits: 10001001

Readiness: 1 2 0 0 0



-------------------------------------------------------------------------------
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: 24470A1BB42E243ED0B-5000

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

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 3B0-920-xx5-17.lbl
Part No: 3B0 920 929 C
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 15235
Shop #: WSC 39035
VCID: 275D1D17C518CF26F59-5000
WVWCE63B95E116080 VWZ7Z0D1096047

1 Fault Found:
01304 - Radio
49-00 - No Communications

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 25016
VCID: F0EFB64BB056489EE43-5072

1 Fault Found:
01304 - Radio
49-00 - No Communications

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 08 Komfortgerát HLO 0001
Coding: 00258
Shop #: WSC 00028
VCID: 377DCD5715B85FA6659-4A9C

Subsystem 1 - Part No: 1C1959801
Component: 80 Tõrsteuer.FS KLO 0202

Subsystem 2 - Part No: 1C1959802
Component: 80 Tõrsteuer.BF KLO 0202

Subsystem 3 - Part No: 1C0959811
Component: 80 Tõrsteuer.HL KLO 0202

Subsystem 4 - Part No: 1C0959812
Component: 80 Tõrsteuer.HR KLO 0202

10 Faults Found:
01330 - Central Control Module for Central Convenience (J393)
53-10 - Supply Voltage Too Low - Intermittent
00928 - Locking Module for Central Locking; Front Driver Side (F220)
54-10 - Incorrectly Equipped - Intermittent
00930 - Locking Module for Central Locking; Rear Left (F222)
54-10 - Incorrectly Equipped - Intermittent
00931 - Locking Module for Central Locking; Rear Right (F223)
54-10 - Incorrectly Equipped - Intermittent
01331 - Door Control Module; Driver Side (J386)
53-10 - Supply Voltage Too Low - Intermittent
01332 - Door Control Module; Passenger Side (J387)
53-10 - Supply Voltage Too Low - Intermittent
01333 - Door Control Module; Rear Left (J388)
53-10 - Supply Voltage Too Low - Intermittent
00930 - Locking Module for Central Locking; Rear Left (F222)
27-10 - Implausible Signal - Intermittent
01334 - Door Control Module; Rear Right (J389)
53-10 - Supply Voltage Too Low - Intermittent
00931 - Locking Module for Central Locking; Rear Right (F223)
27-00 - Implausible Signal

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

Things on my current "to-do" list are:

-Remove and clean out EGR,

-Replace N75 just in case,

-Find O2 sensor and attempt to replace it,

What should I be doing and what have I missed?

Stop randomly replacing parts. Get the car to someone that knows what they are doing and have them properly diagnose it or this will become really expensive really fast.

When you went to look at the, was the engine stone cold or did the seller pull a "warmed it up for you so you can take it out for a test dive" scam?

Are you in the Portland area? If so get the car to Rich at Fix Um Haus and he'll help you diagnose it.

Clean all the grounds.

The MAFs rarely fail on those. If it is some aftermarket unit, it is likely junk. Get a genuine Bosch.

BHW boost issues are super easy to diagnose, as the only thing that is controlled by vacuum on that engine is the turbo. And that is the same as most other TDIs with VNTs. The only real difference is the N75 valve that controls it is located in a hard to access spot down low on the front of the engine. But you can at least check the OTHER ends of all three lines to that area easy enough. Vacuum source from the tube off the vacuum pump that goes to the brake booster, back by the firewall, then goes through the one way check valve near the air cleaner (the black/white piece). The actuator line to the turbo itself, then the third is the vent line that attaches to the top (clean) side of the air cleaner.

VCDS lets you do a VNT Basic Settings, with that going the engine will idle fast and work the VNT up and down, which is easy to watch on the BHW as it is visible. It should move up and down. If it does that, you know the turbo control side is working.

Next would be checking for charge air leaks. There are four hoses, but only two of them ever seem to get splits in them: the S-shaped one down low coming off the turbo that goes to the crossover pipe (accessible from underneath the car), and the L-shaped one going into the intake control flap by the firewall. I have never seen either of the other two hoses to split, but they are on the intercooler side, the little one on the other side of the crossover pipe previously mentioned, down low, and the top side, easily seen near the power steering reservoir and radiator hose area.

I have also seen lots of B5s get broken intercoolers from crash damage. Charge air leaks are easily found with a quick brake torque and listen for a hissing or whooshing sound.

The Garrett turbochargers rarely fail on these.

oilhammer said:

The Garrett turbochargers rarely fail on thes unless the balance shaft mechanism has failed.

Click to expand...

? i need 5 characters

oilhammer said:

Charge air leaks are easily found with a quick brake torque and listen for a hissing or whooshing sound.
The Garrett turbochargers rarely fail on these.

Click to expand...

Thanks for all that, SUPER HELPFUL! The only think that I didn't understand was what do you mean by "a quick brake torque".

I do hear a wooshing sound when the turbo tries to engage.

IndigoBlueWagon said:

Are you in the Portland area? If so get the car to Rich at Fix Um Haus and he'll help you diagnose it.

Click to expand...

Great place from what I hear, I'm planning on visiting them if I can't figure it out, it's just a long way to drive (as well as over the West Hills from me) in limp mode lol

imo000 said:

Stop randomly replacing parts. Get the car to someone that knows what they are doing and have them properly diagnose it or this will become really expensive really fast.

Click to expand...

Thanks, I'm not randomly replacing parts though, these are all cheap parts that are likely related and likely to fail anyway so no harm in replacing them. It's not like I'm just throwing a new turbo into it like the professional I consulted wanted to do with out even looking at it lol

Brake torque:

Pushing the brake pedal firmly down with your left foot, placing the transmission in D or R, then pressing the accelerator down briefly with your right foot.

Cleared the codes, did a brake torque, no sound but I now know what it would look
and feel like is I did a 2-3 lift on the front of the car lol.

Drove it for exactly 5 miles and was able to get it up to 45 mph max.

Here are the current codes(I really thought the electrical ones were due to running the battery down and would go away):

Chassis Type: 3B (3B - VW Passat B5 (1997 > 2005))
Scan: 01 02 03 08 15 16 17 19 35 36 37 46 47 55 56 57 58 75 76 77


VIN: WVWCE63B95E116080
-------------------------------------------------------------------------------
Address 01: Engine Labels: 038-906-016-BHW.lbl
Part No SW: 038 997 016 T HW: 028 101 198 2
Component: R4 2,0L EDC G000AG 0314
Revision: 12345678 Serial number: VWZ7Z0D1096047
Coding: 0150034
Shop #: WSC 23312 444 84483
VCID: 2F6DF537BDE897663D9-5000

1 Fault Found:
16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
RPM: 2352 /min
Torque: 278.0 Nm
Speed: 63.0 km/h
Load: 63.1 %
Voltage: 14.14 V
Bin. Bits: 00001000
Absolute Pres.: 2325.6 mbar
Absolute Pres.: 1519.8 mbar

Readiness: 0 0 1 1 1

-------------------------------------------------------------------------------
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: 6CD7223B4C7E2C7E58B-5072

No fault code found.

-------------------------------------------------------------------------------
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: 2541171FBF14DD36C75-5072

No fault code found.

-------------------------------------------------------------------------------
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: 24470A1BB42E243ED0B-5000

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

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 3B0-920-xx5-17.lbl
Part No: 3B0 920 929 C
Component: KOMBI+WEGFAHRSP VDO V07
Coding: 15235
Shop #: WSC 39035
VCID: 275D1D17C518CF26F59-5000
WVWCE63B95E116080 VWZ7Z0D1096047

No Faults Found
or DTCs not supported by controller
or a communication error occurred

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<->CAN 0001
Coding: 00006
Shop #: WSC 25016
VCID: F0EFB64BB056489EE43-5000

1 Fault Found:
01304 - Radio
49-00 - No Communications

-------------------------------------------------------------------------------
Address 46: Central Conv. Labels: 1C0-959-799.lbl
Part No: 1C0 959 799 C
Component: 08 Komfortgerát HLO 0001
Coding: 00258
Shop #: WSC 00028
VCID: 377DCD5715B85FA6659-4A9C

Subsystem 1 - Part No: 1C1959801
Component: 80 Tõrsteuer.FS KLO 0202

Subsystem 2 - Part No: 1C1959802
Component: 80 Tõrsteuer.BF KLO 0202

Subsystem 3 - Part No: 1C0959811
Component: 80 Tõrsteuer.HL KLO 0202

Subsystem 4 - Part No: 1C0959812
Component: 80 Tõrsteuer.HR KLO 0202

10 Faults Found:
01330 - Central Control Module for Central Convenience (J393)
53-10 - Supply Voltage Too Low - Intermittent
00928 - Locking Module for Central Locking; Front Driver Side (F220)
54-10 - Incorrectly Equipped - Intermittent
00930 - Locking Module for Central Locking; Rear Left (F222)
54-10 - Incorrectly Equipped - Intermittent
00931 - Locking Module for Central Locking; Rear Right (F223)
54-10 - Incorrectly Equipped - Intermittent
01331 - Door Control Module; Driver Side (J386)
53-10 - Supply Voltage Too Low - Intermittent
01332 - Door Control Module; Passenger Side (J387)
53-10 - Supply Voltage Too Low - Intermittent
01333 - Door Control Module; Rear Left (J388)
53-10 - Supply Voltage Too Low - Intermittent
00930 - Locking Module for Central Locking; Rear Left (F222)
27-10 - Implausible Signal - Intermittent
01334 - Door Control Module; Rear Right (J389)
53-10 - Supply Voltage Too Low - Intermittent
00931 - Locking Module for Central Locking; Rear Right (F223)
27-00 - Implausible Signal

End -

PaulC1969 said:

Thanks, I'm not randomly replacing parts though, these are all cheap parts that are likely related and likely to fail anyway so no harm in replacing them. It's not like I'm just throwing a new turbo into it like the professional I consulted wanted to do with out even looking at it lol

Click to expand...

Doesn't matter how much a part costs. If you are replacing it without knowing 100% that is has failed then you are throwing parts at it. That relay doesn't fail as much as you think it does. Replanting it can introduce another point of issue. You replaced a known working part with a new but not known that is works part. I had to deal with something like this in the past and it took a long time to find out that the replaced part was not working while the another part actually caused the original problem. I had to chase two things at once. Test, test and test before changing anything.

Read post #6 again. You either have a boost leak OR the vacuum control portion of the turbocharger is not working correctly. It is a very, very simple system.