No start after fuel filter swap (weird priming issue)

So i replaced the fuel filter on my 05 passat without filling the replacement filter with diesel, tried priming with the key a few times before actually cranking it. Once I did get to cranking it (10 sec on, 30 sec off) it seemed like there was air in the system so I filled the filter up and continued trying to crank the engine until the battery died (probably 20 attempts).

I cycled the key 30 times to try to prime with the in-tank pump then charged the battery up and now getting some light smoke out of the exhaust but also getting P0407 "EGR Sensor 2 value too low" Are these things related? Should i keep priming with the key and cranking it or is there an injector line somewhere I can crack to help the pump out?

cycle key 4 or 5 times and the fuel pump in the tank will fill up the filter.

jumper another battery in parallel with yours then cycle key 5 seconds on 5 seconds off till it starts

afarfalla said:

cycle key 4 or 5 times and the fuel pump in the tank will fill up the filter.
jumper another battery in parallel with yours then cycle key 5 seconds on 5 seconds off till it starts

Click to expand...

I've probably done this about 30 times at this point, along with some longer cranking periods (~30 sec). I have also replaced the new fuel filter with the old one in case there was some blockage, making sure to quickly swap the lines over and fill the "new" old filter with diesel before install. I then used a mityvac to pull vacuum on the return line from the engine and all I got was fuel.

I pulled the hose off the egr and looks like the intake flap is open, It's smoking a little when cranking but I'm still not convinced the air is out of the fuel system. Is there a way to check the injectors are firing?

Update: used VCDS during cranking and am seeing RPM 2-400 RPM and the following codes. Note that I cleared these and they came right back, not sure why they're so persistant

Also am seeing the following under engine group 13 during cranking. Does this mean the ecu isn't commanding any fuel?


Address 01: Engine Labels:
Control Module Part Number:
Component and/or Version:
Software Coding:
Work Shop Code:
VCID: 55AF4D51AC427BE2DE-FFFE
8 Faults Found:

16627 - Solenoid Valve for Boost Pressure Control (N75)
P0243 - 000 - Malfunction
Freeze Frame:
RPM: 0 /min
Torque: 166.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.62 V
Bin. Bits: 00001000
Absolute Pres.: 183.6 mbar
Absolute Pres.: 2182.8 mbar

19557 - Motor for Intake Manifold Flap (V157)
P3101 - 000 - Open or Short to Ground
Freeze Frame:
RPM: 0 /min
Torque: 166.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.62 V
Bin. Bits: 00001000
Torque: 56.0 Nm
Torque: 108.0 Nm

16567 - Fuel Temp. Sensor A (G81)
P0183 - 000 - Open or Short to Plus
Freeze Frame:
RPM: 0 /min
Torque: 166.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.62 V
Temperature: 133.2°C
Temperature: 30.6°C
Temperature: 38.7°C

16497 - Intake Air Temp. Sensor (G42)
P0113 - 000 - Signal too High - Intermittent
Freeze Frame:
RPM: 0 /min
Torque: 166.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.62 V
Temperature: 133.2°C
Temperature: 30.6°C
Temperature: 38.7°C

16622 - Manifold Pressure / Boost Sensor (G31)
P0238 - 000 - Signal too High - Intermittent
Freeze Frame:
RPM: 0 /min
Torque: 166.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.62 V
Bin. Bits: 00001000
Absolute Pres.: 183.6 mbar
Absolute Pres.: 2182.8 mbar

18074 - PD Unit Injector; Cylinder 1 (N240)
P1666 - 000 - Electrical Malfunction
Freeze Frame:
RPM: 504 /min
Torque: 196.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 10.26 V
Inj. Quantity: 0.00 mg/str
Temperature: 38.7°C
(no units): 128.0

18077 - PD Unit Injector; Cylinder 4 (N243)
P1669 - 000 - Electrical Malfunction
Freeze Frame:
RPM: 273 /min
Torque: 202.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 10.49 V
Inj. Quantity: 0.00 mg/str
Temperature: 38.7°C
(no units): 128.0

18076 - PD Unit Injector; Cylinder 3 (N242)
P1668 - 000 - Electrical Malfunction
Freeze Frame:
RPM: 378 /min
Torque: 196.0 Nm
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 10.49 V
Inj. Quantity: 0.00 mg/str
Temperature: 38.7°C
(no units): 128.0

Your battery is bad

UPDATE: It was computer/wiring related as I suspected. Even with the engine off, the codes listed above would pop back up right after clearing them. I noticed most (all?) of those sensors are on the same harness. I opened up the ECU enclosure, made sure all the connectors were seated then connected the battery + and - terminals together for 30 seconds, then it started right up without any codes other than ones I was expecting from my 5 speed swap