B5.5 MY05 2.0 TDi P0299, P0101

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
Ok, I think I'll just sell it, or donate it to Salvation Army or whatever. I'm not gonna put more money into it. Thanks much, guys, for your help throughout this adventure!
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
OK..
  • Valve cover gasket replaced
  • Turbo disassembled, checked end play and wobble: Felt perfect
  • Cleaned Turbo completely - including the VNT section Now it moves like butter. no bent vanes, no sloppiness where the actuator arm moves the ring..
  • New Downpipe gasket, oil drain gasket, EGR Cooler gaskets
  • New hardware (studs, nuts, etc)
  • Checked/cleaned MAF and MAP
  • Checked/cleaned intercooler pipes
  • Removed, cleaned and reinstalled intake manifold, including new gasket
  • WGA tested; holds vacuum as tested
  • Vacuum canister under turbo holds vacuum as tested
Reassembled everything, took it for a drive. Stayed in town, driving around, seemed fine. Spent about 30-40 mins doing this..
Decided now's the time, let's hop on the bypass and get some speed...
Turned onto the on-ramp, accelerated to about 35-40, BEEEEP.. Limp mode.
Went to next exit and pulled over, whipped out the VCDS. P0299.. Requested: 2364mb, 1754.4mb actual.

N75 has been replaced
EGR was cleaned
All vacuum lines replaced
Vacuum check valve replaced
Air Filter replaced

I'm out of guesses, at this point.. Short of buying an EGR blockoff ant 'testing' to see if the EGR is not seating properly, I don't know what else to do..

PLEASE, throw me some ideas, if you have any more.. I'm at my wits end with this car now.
Thanks.
Did I miss you checking how much vacuum you have?
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
Oh, I did notice a very faint blub blub blub sound at idle...sounds like from the air box area, or the intake manifold, from what I could best decipher. Wasn't real loud to me, and I just happened to notice it today. it did not get worse or louder with faster engine speeds. It was very faint.


The only code I'm getting is the P0299.
 
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VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
OK, pulled the cam cover again..
The lobes are quite worn.. I couldn't really see the lifters without tearing everything apart, but the cam lobes were definitely worn. Ridged along the lobe, scuffed a little, and the beveled edge was completely non-existent along the lift of the lobes..
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
OK, pulled the cam cover again..
The lobes are quite worn.. I couldn't really see the lifters without tearing everything apart, but the cam lobes were definitely worn. Ridged along the lobe, scuffed a little, and the beveled edge was completely non-existent along the lift of the lobes..
Sounds like you've found your problem.
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
Sounds like you've found your problem.
you think that's really it? I mean, it's a $500+ guess.. lol
I replaced the N75 (months ago) with a knockoff, thinking that was the issue, but it wasn't. Of course I can't find where I put the original. lol someone else said throw the knockoff away and get a real one.. Again, a $100 guess.. ;)
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
Well, UPDATE:
Got a new cam, lifters, bolts. Pulled it apart, put the new cam in, aligned the tandem pump, timed cam, tried rotating the engine by hand.. it moved about 1" and stopped. backed it back up, rechecked timing marks, all was on point..pulled the cam back out, and saw one of the ears on the tandem pump was broken off.. FML
So I ordered a replacement tandem pump..
I'm also trying to find replacement harmonic balancer bolts, but every thing I find online looks too long. Thoughts?

Wonder if I broke the ear off the tandem pump, or if it was on it's way out. I really don't know how I'd done it, as I was super gentle with putting it all back together..


So now, 900$ in parts later, if this doesn't fix the original issue, I've got about 100 lbs of tannerite that the Passat will get to experience.
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
No love...
NEW:
  • Camshaft
  • Lifters
  • Vacuum Lines
  • Tandem Pump
  • N75
  • Fuel Filter
  • S-Boost hose (turbo outlet)
    • Checked others for cracks, all good
  • Turbo Service - No issue found
  • Air Filter
Checked and/or fixed
  • VNT Actuator - Fine
  • EGR - fine
  • Intake manifold - Not bad, cleaned anyway
  • Timing
I'm sure I'm missing stuff..
Boost pressure/smoke test - no issues found
VNT holds vacuum as intended, operates freely
Vacuum canister functions as intended.

Exhaust always seems to stink.. not like a regular diesel, but smells... idk.. dusty, or musty? hard to explain.

Cleared codes, drove it, took a highway entrance ramp (my normal test route) and low n behold... at about 60mph while accelerating up the on-ramp.. BOOM: limp mode...
Came home P0299..
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
No love...
NEW:
  • Camshaft
  • Lifters
  • Vacuum Lines
  • Tandem Pump
  • N75
  • Fuel Filter
  • S-Boost hose (turbo outlet)
    • Checked others for cracks, all good
  • Turbo Service - No issue found
  • Air Filter
Checked and/or fixed
  • VNT Actuator - Fine
  • EGR - fine
  • Intake manifold - Not bad, cleaned anyway
  • Timing
I'm sure I'm missing stuff..
Boost pressure/smoke test - no issues found
VNT holds vacuum as intended, operates freely
Vacuum canister functions as intended.

Exhaust always seems to stink.. not like a regular diesel, but smells... idk.. dusty, or musty? hard to explain.

Cleared codes, drove it, took a highway entrance ramp (my normal test route) and low n behold... at about 60mph while accelerating up the on-ramp.. BOOM: limp mode...
Came home P0299..
Try installing a plate in the egr inlet hose, an EGR valve that's sticking open can cause a p0299. Plating it off temporarily can rule that out.
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
the upper metal S-pipe thing, where it bolts to the EGR? someone also told me to loosen the three nuts ont he downpipe-to-turbo to see if the exhaust is doing it, too.. IDK.. I'm ready to scream, I know that much.. LOL
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
On your suggestion, I made a blockoff plate for the EGR tube.. no change, other that an EGR Flow code.
On the other suggestion, I backed the 3 downpipe nuts off to the end, and slid the downpipe back, so there was plenty of exhaust escape..

No change on either; I still get the P0299 code.
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI
On your suggestion, I made a blockoff plate for the EGR tube.. no change, other that an EGR Flow code.
On the other suggestion, I backed the 3 downpipe nuts off to the end, and slid the downpipe back, so there was plenty of exhaust escape..

No change on either; I still get the P0299 code.
Monitor the maf desired vs actual while driving and see what you get.
 

Zeitgeist

Veteran Member
Joined
Nov 10, 2004
Location
Cascadia
TDI
'04 Variant and Vanagon mTDI
Sheesh dude, you left us hanging. The legions of limp mode sufferers are awaiting the final outcome.
 

Zeitgeist

Veteran Member
Joined
Nov 10, 2004
Location
Cascadia
TDI
'04 Variant and Vanagon mTDI
I truly understand the frustrated fatigue factor. You've been at this journey for over a year. I've only been after the same limp monkey on my back for about four months, and I'm pulling my hair out already. At least you seem to know how to run diagnostics via VCDS. I'm not there yet.
 

VariantB3_VR6

Well-known member
Joined
Aug 25, 2004
Location
Winchester, VA
TDI
05 B5-A, 01 A4-M
I truly understand the frustrated fatigue factor. You've been at this journey for over a year. I've only been after the same limp monkey on my back for about four months, and I'm pulling my hair out already. At least you seem to know how to run diagnostics via VCDS. I'm not there yet.
I just fake it til I make it :cautious:
 

Zeitgeist

Veteran Member
Joined
Nov 10, 2004
Location
Cascadia
TDI
'04 Variant and Vanagon mTDI
I'm curious how this turns out because I'm concerned that the new cam didn't cure the limping. That's the last bit of hardware options I have, and my cam lobes don't look near as bad as those pics you took.
 
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