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[Solved] VW Passat B5FL 1.6 - It goes out while driving, then turns and does not start

tyszex 13173 15
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  • #1 17122677
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    Volkswagen Passat B5FL sedan
    Born in 2002
    1.6 74kW engine

    Hello.
    The problem has been around for 3 months, no spec could locate the problem so I brainstorm on the forum.
    The car has a problem with starting after a standstill (from 30 minutes to 1.5 hours, variously). When I return to the car after this time, the starter is spinning but the engine does not surprise. After withdrawing the key or several attempts, or after waiting a few minutes, it fires up and continues.
    It also happens that it goes out while driving (also only after 30 minutes to 1.5 hours) - I'm driving, gas in the floor, and suddenly the car behaves as if I did not press the gas pedal at all. The revs drop as if I let the car run (and it is also on gear) to zero, the car goes out and I stand. Then I try to fire again and the situation is similar - I do not want to fire, or it will fire after withdrawing the key or waiting a few minutes, there is no rule, it happens differently.
    The problem only happens when driving or trying to start AFTER STANDSTILL FROM 30 MIN TO 1.5H, WHEN I TRY TO GO OR START AT ENGINE TEMPERATURE OK, 60-70 ST ON CLOCKS. When it is very cold or very warm, there is no problem.

    What was replaced?
    1) Crankshaft position sensor - first on DELPHI, then on the original BOSCH - no improvement.
    2) Fuel filter.
    3) Fuel pump cartridge.
    4) Air filter
    5) Relays that seemed suspicious (electrician replaced).
    6) 2 relays at the computer (I do not know what, unfortunately)

    I am asking for help because there is really no support from anyone, everyone is spreading their hands. Some still suggest an immobilizer or a coil, or some kind of cable that doesn't connect.
    What else to check, what could be the cause?
    I'm counting on help, the car goes out in 4 months.

    Best regards!
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  • #2 17122715
    kindlar
    Level 42  
    Posts: 7819
    Help: 912
    Rate: 1601
    I'll be guessing: the ignition cube.
    You have to take measurements as it turns and does not fire.
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  • #3 17123320
    mateklos
    Level 23  
    Posts: 545
    Help: 50
    Rate: 186
    I also had an ignition switch and immo. Replacing the bcb ignition coils 1 .6 16v.
    Check neglected combed exhaust system if there is no leakage between the manifold and the muffler.
    For me it helped, the mechnik kescze calibrated me by the way, now some riders
    It is worth taking care of these motors because they do 400kkm and ride and this novelty is eee ....
    Diagnostics will come in handy.
    Surely the ignitions on the cylinders are falling out of what you write.
    And how does EVP and Egr look at Cb,
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  • #4 17124344
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    Thank you for your response.
    UPDATE: today I discovered that when I do not want to start, the fuel pump does not turn on when turning the ignition key. You cannot hear her, it only starts when the engine is spinning and refuses to start. When I wait a few minutes and turn on the ignition again, the pump sounds and fires from the arrow. What could it be?
  • #5 17124458
    kindlar
    Level 42  
    Posts: 7819
    Help: 912
    Rate: 1601
    Check the pump relay. If it does not fire, if you give a bridge, it will fire instead of a relay.
  • #6 17124707
    mateklos
    Level 23  
    Posts: 545
    Help: 50
    Rate: 186
    It is possible that Immo cuts off the ignition, that is, giving fuel.
    Gauge, weak battery etc.
    Poor contact on the ignition switch should be so you turn the key and turn on the pump and the rest of the electrics from the spine when the motor stops buzzing, it is ready to work if the contactor is blocked, it is characteristic to tick.
    Turn the buzzer to the ignition position and let it sit for 10 seconds.
    And so a few times until you hear how the pump motor works.
    Then turn the ignition on when it fires, it will burn.
    When you fire up, do not press the acceleration lever because the throttle must set itself automatically. If you move, it can misinterpret fuel and air doses.
    As soon as it fires, check the condition of the ignition coils.
    See if the vacuum hose between the brake servo and throttle valves is tightly connected.
    Before starting, unscrew the plug from the oil in the engine for a while then close it tightly. And only then fire up.

    If it does nothing, then diagnostics and what shows what errors.
  • #7 17128951
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    Today I have time, I will try to check the car.
    kindlar - am I able to do it myself, being a layman in the subject of electrics? If so, I would ask for some tips on how to do it, and if not, I will try to find someone I know.
  • #8 17128970
    kindlar
    Level 42  
    Posts: 7819
    Help: 912
    Rate: 1601
    The two thick contacts in the relay are the contacts from the pump. When you connect them with a cable, the pump should respond.
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  • #9 17128983
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    I understand. I'll try later and let you know what's going on. Do I have to do the whole thing when the car won't start or at any time?
  • #10 17128999
    kindlar
    Level 42  
    Posts: 7819
    Help: 912
    Rate: 1601
    When it goes off to see if it's a pump relay.
  • #11 17162162
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    When it refuses to start, I make a quick shot with the key and I hear both the fuel pump working and the click of the pump relay. So it looks like these aren't the things that are causing the stall and firing problem. Today, during one drive, it went out 3 times, usually when accelerating on a three or four. It goes out, as I said, not right away, but I just lose the ability to pedal the gas, the car does not react to it at all, I wave it as I want and nothing, the speed slowly drops to 0 and that's it.
  • #12 17179567
    mateklos
    Level 23  
    Posts: 545
    Help: 50
    Rate: 186
    -check the operation of the fuel pump
    -check that the ignition does not fall out
    -check the throttles: wrong vacuum, wrong control
    Overall, what are the errors on the obd?

    Check that the second key is the same symptom when firing.
  • #13 17213457
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    ZERO errors. Thread. The second key is the same, it doesn't matter if you replace the key.
  • #14 17219170
    mateklos
    Level 23  
    Posts: 545
    Help: 50
    Rate: 186
    - servo pump tubing and throttle
    - coils and candles
    - Lambda probe
    -and maybe the map was raining
    Delete errors when you start and turn off whatever appears?
    Eventually he could bash the ECU. If there is no error.
    You can check them one by one and wait for exchanges.
    Fuel lines or injectors could also get stuffed.
  • #15 17221209
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    Errors zero, erase, fire up, drive, absolutely nothing appears. Suspect ECU, most parts replaced or checked. I am replacing the coil because I have a new one in stock, and I will be watching. If not, you must hit the ECU.
  • #16 17236795
    tyszex
    Level 4  
    Posts: 94
    Rate: 13
    I don't want to bother you, but the problem was finally solved after six months. The culprit of all the confusion was probably the camshaft position sensor and the cable touching the collector.

Topic summary

✨ The discussion revolves around a 2002 Volkswagen Passat B5FL with a 1.6 74kW engine experiencing intermittent starting issues and stalling while driving. The owner reports that the car fails to start after a standstill, with the starter spinning but the engine not firing. Additionally, the vehicle can stall while driving, losing power and coming to a stop. Various suggestions are made, including checking the ignition switch, fuel pump relay, and ignition coils. The owner discovers that the fuel pump does not activate when the ignition is turned on, leading to further troubleshooting. After several attempts and checks, including the ECU and camshaft position sensor, the issue is eventually resolved, attributed to a faulty camshaft position sensor and a cable touching the collector.
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FAQ

TL;DR: In a VW Passat B5FL 1.6 case, diagnosis took 6 months; “Cam sensor and a chafed wire” fixed repeated warm stalls/no-starts. This FAQ walks you through quick checks for the relay, pump, coils, wiring, and OBD logging to pinpoint similar faults. [Elektroda, tyszex, post #17236795]

Why it matters: For VW Passat B5/B5.5 1.6 16V owners battling intermittent warm stalls and no-starts, this condenses real fixes into fast, low-cost checks.

Quick Facts

What finally fixed the warm stall/no-start on this Passat?

In this case, addressing the camshaft position sensor and a chafed wire near the exhaust collector ended stalls and no-starts. The owner reported the fix after six months of troubleshooting. Heat and vibration can aggravate marginal sensor signals. [Elektroda, tyszex, post #17236795]

Why does my Passat die or refuse to restart after 30–90 minutes and ~60–70°C?

That timing matches the symptom window reported here: 30–90 minutes after standstill and around 60–70°C indicated. The starter cranked, but the engine would not catch. Use that window to reproduce the fault for targeted tests. [Elektroda, tyszex, post #17122677]

How do I test the fuel pump relay fast?

Locate the fuel pump relay and identify its two thick terminals. Bridge them briefly; the pump should run immediately. “The two thick contacts in the relay are the contacts from the pump.” Remove the bridge once verified. [Elektroda, kindlar, post #17128970]

The pump doesn’t prime with ignition but runs during cranking—what does that suggest?

In this thread, the pump sometimes did not prime with ignition, but ran during cranking. Waiting a few minutes restored priming and the engine started. Treat this as an intermittent control issue and retest the relay during the fault. [Elektroda, tyszex, post #17124344]

Can the ignition switch (“ignition cube”) cause intermittent no-starts?

Yes. A worn ignition switch (“ignition cube”) can drop power while starting or running. Measure voltages and signals while it cranks and refuses to fire. “You have to take measurements as it turns and does not fire.” [Elektroda, kindlar, post #17122715]

Is the immobilizer a likely cause if another key behaves the same?

Unlikely in this case. The second key behaved the same, and OBD showed zero errors. Those observations argue against an immobilizer fault. Focus diagnosis on power, sensors, and wiring instead. [Elektroda, tyszex, post #17213457]

Why are there no OBD codes even though it stalls?

This case recorded “ZERO errors,” even after multiple stalls. That edge case shows some intermittent failures will not log faults. Use symptom-based checks and live data while the fault is active. [Elektroda, tyszex, post #17213457]

Which ignition parts should I check first?

Check ignition coils and spark plugs first. A 1.6 16V owner reported improvement after replacing BCB coils. Inspect the exhaust for leaks from the manifold forward. Have the throttle adapted and verify vacuum connections. [Elektroda, mateklos, post #17123320]

Could the ECU be the culprit with no codes?

Yes, consider it only after other checks. The thread suggests the ECU as a possibility when no errors appear. Confirm by substitution or professional testing once wiring and sensors check out. [Elektroda, mateklos, post #17219170]

Is the camshaft position sensor a known trouble point here?

Yes, here the camshaft position sensor proved critical. Addressing it and a chafed wire near the exhaust collector ended warm stalls and no-starts. [Elektroda, tyszex, post #17236795]

How can I capture an intermittent stall during a road test? (3-step)

Follow this plan to catch the fault:
  1. Drive until the symptom appears, then stop safely.
  2. Without cycling the key, scan OBD and record live data and freeze-frames.
  3. Cycle ignition once to note pump prime and relay click for correlation. [Elektroda, mateklos, post #17179567]

The car stalls under acceleration in 3rd/4th and ignores the gas pedal—what should I look at?

Use the repeatable load condition to test. In this case, stalls occurred during acceleration in 3rd or 4th, with no pedal response. During quick key cycles, the pump and relay were heard, guiding checks beyond the pump. [Elektroda, tyszex, post #17162162]

Does replacing the crankshaft position sensor always fix warm stalls?

No. This car had a new Delphi crank sensor, then an original Bosch, without improvement. That history redirected diagnosis toward other components and wiring. [Elektroda, tyszex, post #17122677]

Could injectors or fuel lines be clogged?

Yes, clogged fuel lines or injectors can mimic these symptoms. The thread lists them among items to check once basics are verified. [Elektroda, mateklos, post #17219170]
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