Passat (B5) :: Random Misfires On All 4 Cylinders


Aug 18, 2011

OK. I have a 2005 Passat 1.8t fwd. Tiptronic. 105k

The symptoms i am having is random cylinder misfires on all 4 cylinders. I have scanned with vagcom multiple times and get the same codes. However, I have cleared the codes, and wen fpd a 60 mile drive on the turnpike. Not a single code. So everything is perfect as long as the car dissent have a chance to idle.
I have also driven the car while logging misfires and only get misfires at idle. Never while driving.

So much has been done to the car that is so hard to decide where to start. Ill try to go in order of events.

All this in the past 4 weeks by the way.

Took car to very experienced VW tech. Found out.timing was off by 3 degrees. So new timing belt, water pump and all. Started car, still had misfires. Noticed wetness on head gasket. And did a compression test. Very bad results. (I can't remember the numbers but they were way off from each other) So he removed the head. He said there was a crazy amount of carbon buildup in the combustion chamber. Everything was cleaned, head inspected for bent valves and everything looked perfect after cleaning. (this car has NEVER overheated by the way) He said it is very rare for a head gasket to fail on 1.8t's . So he did a leakdown test and turned out the piston rings were shot. So engine was rebuilt. All components cleaned of carbon, replaced all parts, bearings with new OEM parts. Pickup tube cleaned along with other oil lines. Turbo was inspected, and I was told it is on its way out but still has life. So that was let go for now. All reassembled and all hoses checked, combi valve cleaned, new k&n filter in stock airbox. So he told me the car is finished after all that. I was excited! Drove the car home 15 min drive, ran great. Parked in my driveway, put it in park and misfires came right back. Called him the next day and brought the car back. He looked over it and replaced the fuel pressure regulator with new. He said it seemed like a fuel starvation issue. Tested fuel pump and it was towards the low end of the proper operation value. So I had a high flow pump sitting at home brand new and I brought it down and put it in. Still misfires but a lot less than before. Also fuel filter was replaced. So next he disconnected the cat And found it was clogged. Replaced with my old Audi one, and it ran fine. And this is the first time the car idled good enough to get all the monitors set for emissions testing. So he was convinced it was fixed. Room it for a test drive and came back, parked And began misfiring again. So I was so sick of this thing at this point, I told him to replace the Turbo with brand new OEM unit. And it still misfires.

He swapped a known good throttle body into it and no difference. He also said that he started going around and unplugging sensors and the more sensors he unplugged, the better the car ran. He was curious whether the ECU was faulty. So he put an ECU from his Audi in it which had a ko4 file in it. He said it ran amazing!! So he modified an ECU from a stock Audi and that's what I am driving with now. Still same symptoms. But not as often. Also brand new bosch mass air sensor was installed as well. So this is as far as we have gotten with it and I am so sick of this car right now. But we are both determined to get this thing fixed! And after all the money I have just spent, I can't even get rid of it or I will lose a lot of money. It really sucks because I love the car and so does my wife. And out of the three 1.8t's that I own, I have never had any major issues like this.

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