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Thread: Excessive Smoke, rough idle and occasional knocking

  1. #1
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    Excessive Smoke, rough idle and occasional knocking

    Hey Gents

    I just bought a 2007 t5 2.5 tdi cab chassis BNZ (engine code) off a scrap metal merchant, who had bought if off someone else. He started it briefly but thought the engine was knackered because it was very noisy - so sold it on to me for parts.

    First thing I did was check fluids. 5 litres of oil later it idled really nice. Thought I’d fixed it even though the engine warning light was on. At this stage I didn’t notice it blowing any smoke.

    I then tried to take it for a drive but quickly noticed it was surging, coughing and the occasional knock whilst trying to accelerate - like the timing was out. I put her straight into reverse and attempted to drive it back up hill into my garage. It wouldn’t rev over say 1200 rpm, but after shutting it off and then back on I managed to get it back up in there. Obviously in limp mode. I noticed it was blowing plenty of smoke and leaking oil when under pressure.

    I then bought a Ross Tech cable and it found 2 engine faults. Here is the complete read out

    Code:
    2 Faults Found:
    001137 - Exhaust Pressure Sensor 1 
                   P0471 - 000 - Implausible Signal
                 Freeze Frame:
                        Fault Status: 01110000
                        Fault Priority: 2
                        Fault Frequency: 1
                        Reset counter: 255
                        Time Indication: 0
    
                 Freeze Frame:
                        RPM: 0 /min
                        Speed: 0.0 km/h
                        (no units): 132.60
                        (no units): -5.10
                        (no units): 0.0
                        Temperature: 114.0°C
                        Temperature: 30.6°C
    
    000260 - Mass Air Flow Sensor (G70) 
                   P0104 - 000 - Intermittent - Intermittent
                 Freeze Frame:
                        Fault Status: 00100000
                        Fault Priority: 1
                        Fault Frequency: 8
                        Reset counter: 255
                        Mileage: 274515 km
                        Time Indication: 0
    
                 Freeze Frame:
                        RPM: 0 /min
                        Speed: 0.0 km/h
                        Load: 100.0 %
                        Duty Cycle: 100.6 %
                        Bin. Bits: 00000100
                        Mass Air / Rev.: 525.0 mg/str
                        Mass Air / Rev.: 175.0 mg/str
    
    Readiness: 1 2 0 0 0 
    
    ------------------------------------------------------------------------------- 
    Address 03: ABS Brakes        Labels:. 7H0-907-37x-ABS.clb
       Part No SW: 7H0 907 379 P    HW: 7H0 907 379 P
       Component: (M)ABS MK25E        0103  
       Revision: 00H12001    
       Coding: 0000091
       Shop #: WSC 35110 377 00190
       VCID: 42DD4CE9F89B2E8B056-5160
    
    1 Fault Found:
    00668 - Supply Voltage Terminal 30 
                002 - Lower Limit Exceeded - Intermittent
                 Freeze Frame:
                        Fault Status: 00100010
                        Fault Priority: 2
                        Fault Frequency: 1
                        Reset counter: 40
                        Mileage: 274515 km
                        Time Indication: 0
    
                 Freeze Frame:
                        Count: 0
                        Count: 6145
                        Count: 128
                        Count: 0
    
    
    -------------------------------------------------------------------------------
    Address 08: Auto HVAC        Labels: Redir Fail!
       Part No: 7H0 820 045 AM
       Component: CLIMA/AC            0303  
       Shop #: WSC 00000 000 00000
       VCID: 70B9D62186B7EC1BA32-5160
    
    2 Faults Found:
    00668 - Supply Voltage Terminal 30 
                001 - Upper Limit Exceeded - Intermittent
    01299 - Diagnostic Interface for Data Bus (J533) 
                013 - Check DTC Memory - Intermittent
    
    -------------------------------------------------------------------------------
    Address 09: Cent. Elect.        Labels:. 7H0-937-049.lbl
       Part No: 7H0 937 049 T
       Component: BORDNETZ SGVER 1.0  2001  
       Coding: 0000101
       Shop #: WSC 35110 377 00190
       VCID: 43D349EDE78127830E0-5160
    
    4 Faults Found:
    00991 - Interior Lights 
                012 - Electrical Fault in Circuit - Intermittent
    01598 - Drive Battery Voltage 
                001 - Upper Limit Exceeded
    01598 - Drive Battery Voltage 
                002 - Lower Limit Exceeded
    00538 - Reference Voltage 
                014 - Defective
    
    -------------------------------------------------------------------------------
    Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
       Part No: 1C0 909 605 A
       Component: 3H AIRBAG VW51      0010  
       Coding: 13128
       Shop #: WSC 35110  
       VCID: 221DEC691DDB0E8B656-5160
    
    1 Fault Found:
    00532 - Supply Voltage B+ 
                07-10 - Signal too Low - Intermittent
    
    -------------------------------------------------------------------------------
    Address 17: Instruments        Labels: 7Hx-920-xxx-17.lbl
       Part No: 7H0 920 851 R
       Component: KOMBI+WEGFAHRSP VDO V02  
       Coding: 02703
       Shop #: WSC 00001  
       VCID: 3A2D3409954B664B5D6-5160
       WV3ZZZ7JZ7X023399     VWZ7Z0G5243974
    
    2 Faults Found:
    01316 - ABS Control Module 
                49-10 - No Communications - Intermittent
    01336 - Company Data Bus for Comfort System 
                80-10 - Single-Wire Operation - Intermittent
    
    -------------------------------------------------------------------------------
    Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
       Part No: 6N0 909 901 
       Component: Gateway K<->CAN    0001  
       Coding: 00022
       Shop #: WSC 35110  
       VCID: 70B9D62183B7EC1BA32-5160
    
    2 Faults Found:
    01316 - ABS Control Module 
                49-10 - No Communications - Intermittent
    01336 - Company Data Bus for Comfort System 
                80-10 - Single-Wire Operation - Intermittent
    
    -------------------------------------------------------------------------------
    Address 22: AWD        Labels: 7H0-907-554.clb
       Part No: 7H0 907 554 F
       Component: HALDEX 4Motion      2110  
       Coding: 0000002
       Shop #: WSC 35110 377 00190
       VCID: 3333192DB72197039E0-5160
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 46: Central Conv.        Labels: 7H0-959-433.lbl
       Part No: 7H0 959 433 B
       Component: CX6 Komfortgerát     0004  
       Coding: 00031
       Shop #: WSC 35110  
       VCID: 323D1C294D3B9E0B956-4B1E
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
       Part No SW: 7H0 035 152 C    HW: 7H0 035 152 C
       Component: Radio DE2           0004  
       Revision: 00004000    Serial number: VWZ4Z4F9230269
       Coding: 0020200
       Shop #: WSC 35110 377 00190
       VCID: 221DEC6918DB0E8B656-5160
    
    No fault code found.
    
    End----(Elapsed Time: 05:05, VBatt start/end: 12.0V/12.0V. VIgn 12.0V)-----
    I then replace the Exhaust Pressure Sensor with a new original VW and coded it to the car and also cleaned the Mass Air Flow Sensor with the correct cleaner but nothing changed.

    I have added a couple of links to YouTube. One shows the intermittent sound it’s making and the other shows how much smoke it’s blowing.

    Sound
    https://youtu.be/RpIwZgSPhTM

    Smoke
    https://youtu.be/Tp8ZixZ-rR4


    Any ideas would be greatly appreciated. I’m now leaning towards injector seals but I’m no expert.
    Last edited by Uwe; 04-19-2020 at 09:39 AM. Reason: CODE tags

  2. #2
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    If you could post the "Complete" autoscan then it would be a help.

  3. #3
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    Thanks Viking, is this what you mean....Noob here

    Code:
    Tuesday,14,April,2020,21:25:44:20473
    VCDS -- Windows Based VAG/VAS Emulator Running on Windows 10 x64
    VCDS Version: 20.4.0.1 (x64)  HEX-V2 CB: 0.4508.4
    Data version: 20200331 DS317.0
    www.Ross-Tech.com
    
    
    VIN: WV3ZZZ7JZ7X023399   License Plate: 
    Mileage: 274510km-170572mi   Repair Order: 
    
    
    
    --------------------------------------------------------------------------------
    --------------------------------------------------------------------------------
    
    
    Chassis Type: 7J (7J - VW Transporter Single/Double Cab (2003 > 2010))
    Scan: 01 02 03 08 09 0B 15 16 17 18 19 1C 22 37 45 46 47 56 6E 76
              77 7D
     
    VIN: WV3ZZZ7JZ7X023399   Mileage: 274510km-170572miles
    -------------------------------------------------------------------------------
    Address 01: Engine        Labels: 070-906-016-BPC.clb
       Part No SW: 070 997 016 M    HW: 070 997 016 M
       Component: R5 2,5L EDC  000SG  0860  
       Revision: --H05---    Serial number: VWZ7Z0G5243974
       Coding: 0051172
       Shop #: WSC 00199 551 00000
       VCID: 2411EA7102CF00BB17A-5184
    
    2 Faults Found:
    001137 - Exhaust Pressure Sensor 1 
                   P0471 - 000 - Implausible Signal
                 Freeze Frame:
                        Fault Status: 01110000
                        Fault Priority: 2
                        Fault Frequency: 1
                        Reset counter: 255
                        Time Indication: 0
    
                 Freeze Frame:
                        RPM: 0 /min
                        Speed: 0.0 km/h
                        (no units): 132.60
                        (no units): -5.10
                        (no units): 0.0
                        Temperature: 114.0°C
                        Temperature: 30.6°C
    
    000260 - Mass Air Flow Sensor (G70) 
                   P0104 - 000 - Intermittent - Intermittent
                 Freeze Frame:
                        Fault Status: 00100000
                        Fault Priority: 1
                        Fault Frequency: 8
                        Reset counter: 255
                        Mileage: 274515 km
                        Time Indication: 0
    
                 Freeze Frame:
                        RPM: 0 /min
                        Speed: 0.0 km/h
                        Load: 100.0 %
                        Duty Cycle: 100.6 %
                        Bin. Bits: 00000100
                        Mass Air / Rev.: 525.0 mg/str
                        Mass Air / Rev.: 175.0 mg/str
    
    Readiness: 1 2 0 0 0 
    
    ------------------------------------------------------------------------------- 
    Address 03: ABS Brakes        Labels:. 7H0-907-37x-ABS.clb
       Part No SW: 7H0 907 379 P    HW: 7H0 907 379 P
       Component: (M)ABS MK25E        0103  
       Revision: 00H12001    
       Coding: 0000091
       Shop #: WSC 35110 377 00190
       VCID: 42DD4CE9F89B2E8B056-5160
    
    1 Fault Found:
    00668 - Supply Voltage Terminal 30 
                002 - Lower Limit Exceeded - Intermittent
                 Freeze Frame:
                        Fault Status: 00100010
                        Fault Priority: 2
                        Fault Frequency: 1
                        Reset counter: 40
                        Mileage: 274515 km
                        Time Indication: 0
    
                 Freeze Frame:
                        Count: 0
                        Count: 6145
                        Count: 128
                        Count: 0
    
    
    -------------------------------------------------------------------------------
    Address 08: Auto HVAC        Labels: Redir Fail!
       Part No: 7H0 820 045 AM
       Component: CLIMA/AC            0303  
       Shop #: WSC 00000 000 00000
       VCID: 70B9D62186B7EC1BA32-5160
    
    2 Faults Found:
    00668 - Supply Voltage Terminal 30 
                001 - Upper Limit Exceeded - Intermittent
    01299 - Diagnostic Interface for Data Bus (J533) 
                013 - Check DTC Memory - Intermittent
    
    -------------------------------------------------------------------------------
    Address 09: Cent. Elect.        Labels:. 7H0-937-049.lbl
       Part No: 7H0 937 049 T
       Component: BORDNETZ SGVER 1.0  2001  
       Coding: 0000101
       Shop #: WSC 35110 377 00190
       VCID: 43D349EDE78127830E0-5160
    
    4 Faults Found:
    00991 - Interior Lights 
                012 - Electrical Fault in Circuit - Intermittent
    01598 - Drive Battery Voltage 
                001 - Upper Limit Exceeded
    01598 - Drive Battery Voltage 
                002 - Lower Limit Exceeded
    00538 - Reference Voltage 
                014 - Defective
    
    -------------------------------------------------------------------------------
    Address 15: Airbags        Labels: 6Q0-909-605-VW5.lbl
       Part No: 1C0 909 605 A
       Component: 3H AIRBAG VW51      0010  
       Coding: 13128
       Shop #: WSC 35110  
       VCID: 221DEC691DDB0E8B656-5160
    
    1 Fault Found:
    00532 - Supply Voltage B+ 
                07-10 - Signal too Low - Intermittent
    
    -------------------------------------------------------------------------------
    Address 17: Instruments        Labels: 7Hx-920-xxx-17.lbl
       Part No: 7H0 920 851 R
       Component: KOMBI+WEGFAHRSP VDO V02  
       Coding: 02703
       Shop #: WSC 00001  
       VCID: 3A2D3409954B664B5D6-5160
       WV3ZZZ7JZ7X023399     VWZ7Z0G5243974
    
    2 Faults Found:
    01316 - ABS Control Module 
                49-10 - No Communications - Intermittent
    01336 - Company Data Bus for Comfort System 
                80-10 - Single-Wire Operation - Intermittent
    
    -------------------------------------------------------------------------------
    Address 19: CAN Gateway        Labels: 6N0-909-901-19.lbl
       Part No: 6N0 909 901 
       Component: Gateway K<->CAN    0001  
       Coding: 00022
       Shop #: WSC 35110  
       VCID: 70B9D62183B7EC1BA32-5160
    
    2 Faults Found:
    01316 - ABS Control Module 
                49-10 - No Communications - Intermittent
    01336 - Company Data Bus for Comfort System 
                80-10 - Single-Wire Operation - Intermittent
    
    -------------------------------------------------------------------------------
    Address 22: AWD        Labels: 7H0-907-554.clb
       Part No: 7H0 907 554 F
       Component: HALDEX 4Motion      2110  
       Coding: 0000002
       Shop #: WSC 35110 377 00190
       VCID: 3333192DB72197039E0-5160
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 46: Central Conv.        Labels: 7H0-959-433.lbl
       Part No: 7H0 959 433 B
       Component: CX6 Komfortgerát     0004  
       Coding: 00031
       Shop #: WSC 35110  
       VCID: 323D1C294D3B9E0B956-4B1E
    
    No fault code found.
    
    -------------------------------------------------------------------------------
    Address 56: Radio        Labels: 1K0-035-1xx-56.lbl
       Part No SW: 7H0 035 152 C    HW: 7H0 035 152 C
       Component: Radio DE2           0004  
       Revision: 00004000    Serial number: VWZ4Z4F9230269
       Coding: 0020200
       Shop #: WSC 35110 377 00190
       VCID: 221DEC6918DB0E8B656-5160
    
    No fault code found.
    
    End----(Elapsed Time: 05:05, VBatt start/end: 12.0V/12.0V. VIgn 12.0V)-----
    Last edited by Uwe; 04-19-2020 at 09:40 AM. Reason: CODE tags

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  5. #4
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    Yeah, that's better. The first scan missed off the important data about your engine ECU software etc. which will probably be needed if someone can help you.

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  7. #5
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    Quote Originally Posted by Viking View Post
    Yeah, that's better. The first scan missed off the important data about your engine ECU software etc. which will probably be needed if someone can help you.
    I see, well thanks again mate, I appreciate it

  8. #6
    Benevolent Dictator Uwe's Avatar
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    OP is now Verified. Moving to Car Repair Support.

    -Uwe-
    Lock-down of sick people: Quarantine
    Lock-down of healthy people: Tyranny

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  10. #7
    NostraJackAss Jack@European_Parts's Avatar
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    A whole bunch of firmware update levels needed huh?

    Check for hung up injector and fix MAF yet?
    European Parts Emporium/Performance / Immobilizer Solutions EPE
    Certified Master Trained NY/BAR/BAD 7076062/ASE/SAE/NASTF Legal Factory Authorized/Licensed GeKo/FaZit # 403738
    Specializing in Custom Services IE: "welding-fabrication" / EPA-SMOG Update or Pass-Thru-Programming / Data Transfer / Immobilizers & OEM Quality Parts
    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
    www.FixMyEuro.com <<<<<CLICK HERE! or vwemporium@aol.com ( JPPSG & Unverified members need not PM me & Please don't email or call facility for free tech support...use the forum )
    Getting you CONTROL again of your property - TAKE IT! In Conjunction with.........

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  12. #8
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    Quote Originally Posted by Jack@European_Parts View Post
    A whole bunch of firmware update levels needed huh?

    Check for hung up injector and fix MAF yet?
    Thanks for your input Jack. I cleaned the MAF sensor but I might put the one off my other van just to eliminate the possibility the sensor is okay.

    Do I have to physically inspect the injectors to see if any are hung or is there some sort of other test I can do?

    I’ll also look into how I’d go about getting update firmware levels from VCDS and post them.

  13. #9
    NostraJackAss Jack@European_Parts's Avatar
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    Did you isolate zyl that fire to see EGT of each port with infrared camera or laser guided gun thermometer?
    I'd start with pulling the VC and inspection of lifters and rocker arms for physical visual damage and then probably pull all injectors to bench test after a compression check and leak down test of zyl and each isolated injector.
    European Parts Emporium/Performance / Immobilizer Solutions EPE
    Certified Master Trained NY/BAR/BAD 7076062/ASE/SAE/NASTF Legal Factory Authorized/Licensed GeKo/FaZit # 403738
    Specializing in Custom Services IE: "welding-fabrication" / EPA-SMOG Update or Pass-Thru-Programming / Data Transfer / Immobilizers & OEM Quality Parts
    Above Magic! No Written record, AUTO-SCAN or Appointment = NO HELP!
    www.FixMyEuro.com <<<<<CLICK HERE! or vwemporium@aol.com ( JPPSG & Unverified members need not PM me & Please don't email or call facility for free tech support...use the forum )
    Getting you CONTROL again of your property - TAKE IT! In Conjunction with.........

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  15. #10
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    Quote Originally Posted by Jack@European_Parts View Post
    Did you isolate zyl that fire to see EGT of each port with infrared camera or laser guided gun thermometer?
    I'd start with pulling the VC and inspection of lifters and rocker arms for physical visual damage and then probably pull all injectors to bench test after a compression check and leak down test of zyl and each isolated injector.
    Have ordered a laser thermometer and am I correct by saying you meant aim the laser on each exhaust port to see if any have a much lower reading, therefore a dead cylinder so to speak? I’ll check that out prior to removing the valve cover. Best I get both a compression and leak down tester whilst I’m at it.

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