Trouble shooting Rough Idle, and White smoke 05 Touareg 3.0L V6

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triscuitd

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Hello all, Picked up an 05 Touareg 3.0L v6 TDI with some issues as a project to see if I could tackle it. See scan Below for fault codes. Car has a rough idle with white smoke. Car will drive once you get the engine over 2000 RPM with spikes in RPM intermittently. Below 2000 RPM the car is crawling with lots of white smoke which im assuming is unburned fuel. Checked all the basic signs for a blown head gasket. (Low coolant, Frothy oil, overheating) All seemed to be fine. Ran a Full scan and found fails for all injectors. Watching MVB 013 and 014 showed injectors on both banks were out of limits for +- 2.99 mg/str. They were all sitting at +- 4 - 6 mg/str. Watching MVB 013 and 014 is that sure sign that the injectors are really bad? Both fuel pumps seemed to be ok. High pressure pump was sitting steady at like 248-252 BAR. Don't know if there is a MVB for low pressure pump but I could hear it humming when I put the key in the ignition and the car starts so I figure that one is fine as well. The fuel filter is brand new. Inspected filter housing for dirt, debris, and clogged lines it checked out ok. Id like to run the injectors on a test set to see if they are leaking but is that something I could know by watching MVB 013 and 014? Im not familiar with exactly what the value +- 2.99 mg/str means but ive done some reading and I guess that's a way to identify if one is leaking? What other things should I be checking? If you guys have any questions ask away. Thanks!

A few side notes
Previous owner put Red dye Diesel fuel in the tank and claimed issues started shortly after that. Red dye is far as I know has the same quality's as normal diesel its just untaxed and illegal.
Air filter has been checked and ok
Swirl flap actuator rod for the (my left looking in) (engine side right) had been disconnected and needs readjusted which I have since done. Pretty sure this is the reason for the very first fault code.

Code:
Tuesday,15,September,2020,13:34:32:09338
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
VCDS Version: 20.4.2.0 (x64) HEX-V2 CB: 0.4513.4
Data version: 20200730 DS317.0
[URL="http://www.Ross-Tech.com"]www.Ross-Tech.com[/URL]


VIN: WVGZZZ7LZ5D063577   License Plate:


Chassis Type: 7L (7L - VW Touareg (2003 > 11/2006))
Scan: 01 02 03 05 06 08 09 11 13 15 16 17 18 19 1C 22 29 32 34 36
37 39 3C 46 47 55 56 57 64 65 68 69 6C 6D 6E 75 76 77

VIN: WVGZZZ7LZ5D063577 Mileage: 260280km-161730miles
-------------------------------------------------------------------------------
Address 01: Engine Labels: 059-907-401-ASB.clb
Part No SW: 7L0 907 401 HW: 8E0 907 401 AB
Component: 3.0L V6TDI G001AG 0110
Revision: --H02--- Serial number: VWZ3Z0E1308970
Coding: 0011779
Shop #: WSC 80093 222 69422
   VCID: 6889BE996E619CEBFA3-5160

7 Faults Found:
012597 - Intake Manifold Runner Control
P3135 - 001 - Lower Stop not Reached - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 5
Reset counter: 255
Mileage: 260287 km
                    Time Indication: 0

             Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Speed: 0.0 km/h
Voltage: 12.46 V
Duty Cycle: 88.8 %
Duty Cycle: 20.5 %
                    Duty Cycle: 20.5 %

004663 - Fuel Injector for Cylinder 1 (N30)
P1237 - 001 - Open Circuit - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 1302 /min
Torque: 85.8 Nm
Speed: 0.0 km/h
Inj. Quantity: 9.6 mg/str
Voltage: 12.62 V
Pressure: 411.8 bar
                    Temperature: 19.8°C

004664 - Fuel Injector for Cylinder 2 (N31)
P1238 - 001 - Open Circuit - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 693 /min
Torque: 124.8 Nm
Speed: 0.0 km/h
Inj. Quantity: 19.5 mg/str
Voltage: 14.06 V
Pressure: 241.4 bar
                    Temperature: 20.7°C

004665 - Fuel Injector for Cylinder 3 (N32)
P1239 - 001 - Open Circuit
Freeze Frame:
Fault Status: 01100001
Fault Priority: 0
Fault Frequency: 3
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 714 /min
Torque: 85.8 Nm
Speed: 0.0 km/h
Inj. Quantity: 10.7 mg/str
Voltage: 14.06 V
Pressure: 255.6 bar
                    Temperature: 21.6°C

004672 - Fuel Injector for Cylinder 4 (N33)
P1240 - 001 - Open Circuit - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 756 /min
Torque: 89.7 Nm
Speed: 0.0 km/h
Inj. Quantity: 10.4 mg/str
Voltage: 14.21 V
Pressure: 262.7 bar
                    Temperature: 23.4°C

004674 - Fuel Injector for Cylinder 6 (N84)
P1242 - 001 - Open Circuit - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 756 /min
Torque: 74.1 Nm
Speed: 0.0 km/h
Inj. Quantity: 8.5 mg/str
Voltage: 14.14 V
Pressure: 262.7 bar
                    Temperature: 22.5°C

004673 - Fuel Injector for Cylinder 5 (N83)
P1241 - 001 - Open Circuit - Intermittent
Freeze Frame:
Fault Status: 00100001
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 260288 km
                    Time Indication: 0

             Freeze Frame:
RPM: 756 /min
Torque: 74.1 Nm
Speed: 0.0 km/h
Inj. Quantity: 8.8 mg/str
Voltage: 14.14 V
Pressure: 262.7 bar
                    Temperature: 21.6°C

Readiness: 1 3 0 0 0

-------------------------------------------------------------------------------
Address 02: Auto Trans Labels: 09D-927-750.clb
Part No: 09D 927 750 D
Component: AL 750 6A 0655
Coding: 0004200
Shop #: WSC 31414 000 00000
   VCID: 2F3B15858B0F0BD3FB9-5160

No fault code found.

-------------------------------------------------------------------------------
Address 03: ABS Brakes Labels: 7L0-907-379-MK25.lbl
Part No: 7L0 907 379 G
Component: ESP ALLRAD MK25 0203
Coding: 0014338
Shop #: WSC 31414 000 00000
   VCID: 3D273FCD5163E943795-5160

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. Labels: 3D0-909-13x-05.lbl
Part No SW: 3D0 909 135 N HW: 5WK 470 21
Component: Kessy 6610
Revision: 66105312 Serial number: VWZ3Z0E1308970
Coding: 0000232
Shop #: WSC 31414 000 00000
   VCID: 303916F99631142BE23-5160

   Subsystem 1 - Part No: XXXXXXXXXXX
   Component: ELV                 XXXX

1 Fault Found:
01176 - Key
            004 - No Signal/Communication - Intermittent

-------------------------------------------------------------------------------
Address 08: Auto HVAC Labels: 7L6-907-040.clb
Part No: 7L6 907 040 H
Component: CLIMAtronic R/L X 3716
Coding: 0000030
Shop #: WSC 31414 000 00000
   VCID: 353727ED69533103B15-5160

2 Faults Found:
01592 - Air Quality Sensor (G238)
014 - Defective
00445 - Loss of Refrigerant
000 - -
Freeze Frame:
Temperature: 91.0°C
RPM: 768 /min
Absolute Pres.: 4.0 bar
Load: 99.0 %
Temperature: 21.0°C
Temperature: 23.0°C
Load: 0.0 %
                    Temperature: 88.0°C


-------------------------------------------------------------------------------
Address 09: Cent. Elect. Labels:. 7Lx-937-049-V1.clb
Part No: 7L6 937 049 M
Component: 3001
Coding: 0099556
Shop #: WSC 31414 000 00000
   VCID: 46D5502104B5AA9B28F-5160

1 Fault Found:
02195 - Dimmer Switch Instrument Panel & Switch Lighting (E20)
            008 - Implausible Signal - Intermittent

-------------------------------------------------------------------------------
Address 15: Airbags Labels: 3D0-909-601.lbl
Part No: 3D0 909 601 F
Component: 0B Airbag 8.4E+ H11 1151
Coding: 0012354
Shop #: WSC 31414 000 00000
   VCID: 2615F0A1A4F54A9B08F-5160

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel Labels: 7L6-953-549.lbl
Part No: 7L6 953 549 D
Component: Lenksäulenmodul 3301
Coding: 0000031
Shop #: WSC 31414 000 00000
   VCID: 40D94639269184AB123-5160

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments Labels: 7L6-920-xxx-7LA.lbl
Part No: 7L6 920 970 Q
Component: KOMBIINSTRUMENT RB8 2035
Coding: 0007411
Shop #: WSC 00896 210 92218
   VCID: 45D7572D39B3A183215-5160

1 Fault Found:
00470 - Company Comfort Databus in Single Wire
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 18: Aux. Heat Labels: 7L6-819-008.clb
Part No: 7L6 815 071 C
Component: Standheizung E1MAC
Coding: 0000000
Shop #: WSC 31414 000 00000
   VCID: 323D1CF1983D263B947-5160

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway Labels: 6N0-909-901-19.lbl
Part No: 6N0 909 901
Component: Gateway K<>CAN 0101
Coding: 0000006
Shop #: WSC 31414 000 00000
   VCID: 70B9D6F956B1542BA23-5160

1 Fault Found:
00470 - Company Comfort Databus in Single Wire
            011 - Open Circuit

-------------------------------------------------------------------------------
Address 22: AWD Labels: None
Part No: 0AD 927 755 BE
Component: TRANSFERCASE 0122
Shop #: WSC 00000 000 00000
   VCID: 7F5B05C51BEF3B532B9-5160

No fault code found.

-------------------------------------------------------------------------------
Address 29: Left Light Labels: 3D0-909-157.lbl
Part No: 3D0 909 157
Component: EVG GDL+AutoLWR(l) 0001
Coding: 0000002
Shop #: WSC 31414 000 00000
   VCID: 6695B0A164758A9BC8F-5184

1 Fault Found:
00776 - Level Control System Sensor; Left Front (G78)
            008 - Implausible Signal - MIL ON

-------------------------------------------------------------------------------
Address 39: Right Light Labels: 3D0-909-158.lbl
Part No: 3D0 909 158
Component: EVG GDL+AutoLWR(r) 0001
Coding: 0000002
Shop #: WSC 31414 000 00000
   VCID: 678BBDA5637F9393F39-5184

1 Fault Found:
00776 - Level Control System Sensor; Left Front (G78)
            008 - Implausible Signal - MIL ON
 
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Uwe

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The fact that all six injectors have intermittent open circuit codes would make me want to look for something electrical that they have in common. Got a wiring diagram?

-Uwe-
 
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triscuitd

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The fact that all six injectors have intermittent open circuit codes would make me want to look for something electrical that they have in common. Got a wiring diagram?

-Uwe-
I was leaning that way as well. I just haven’t shot the injector connectors for power or grounds yet. I don’t have a wiring diagram. I’ll look for one later today
 

triscuitd

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*Update*

So fault codes for fuel injectors turned out just to be one of the connectors was not seated all the way. Reseated all connectors and fuel control fuse and everything cleared however the issue remained.

I figured something was still wrong with the fuel injectors and I pulled them to do a visual inspection and have them tested on a bench for spray pattern. During removal I found the "smoking gun". Three valve fingers/rockers were broken off and laying under the valve cover on the left side of the engine. Only the left side had damage not sure how that happened. I figured the engine timing was off however the car still runs. Is that possible for it to be out of time and still run? The cam took some damage and might need replacing not sure yet. Still gotta inspect the timing chain and piston heads. Seems like I need to pull the engine to progress any further. Ive been doing some reading and found that the chain tensioner's on the Tuaregs are poorly designed, does anyone have experience with this issue. Im assuming a loose timing chain caused this engine catastrophe but wont know till I get a chance to look at it. Crazy that it still runs.









 
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