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VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation

niedzwiadek18 38316 20
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Why does my VW Passat B6 2.0 FSI BVY idle unevenly and seem to misfire at low RPM even though compression, spark, injectors, and intake leaks seem OK?

The rough idle was not solved by the disconnected EGR; the eventual cause was a worn/stuck cam phase variator (VVT adjuster), where the washer inside was worn and wedged in its bore, and replacing that damaged variator fixed the engine completely [#17534190] One reply had already pointed at the variable valve timing valve/phase valve as the likely culprit, and the later fix confirmed that direction [#17437940][#17534190] The OP also cleaned the small strainer between the head and the timing chain housing, which was part of the repair [#17534190] A later follow-up noted that on similar Passat/Audi engines the same symptom was also cured by the phase valve / ZFR wheel, with the warning to clean the small filter and use the correct rings during replacement [#20232262]
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  • #1 17437636
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Hello, I have a passat b6 with 2.0FSI code BVY 150KM. The car reached me with a non-smoking engine. Vag showed an error with egr ... after disconnecting it, the engine lights up normally and the suction works nicely :) while when the speed drops, the kennel works as if it were going to 3 cylinders ... on lightly pressed gas about 1300 turns it works perfectly. Currently, the error is from the mentioned EGR because it is disconnected (water got into the valve and everything rotten in it) can the engine go like this because of the disconnected valve? Physically the EGR is closed and tight. In the course of everyone feel nothing, power is.

    Unfortunately, I do not know how the car went before the fault ... maybe someone was already driving with such a jerk until he stopped smoking through this egr.

    - Compression pressure of 12 bar on each cyl.
    - A spark on every candle
    - Somebody has already cleaned the valves and carbon deposit
    - new pneumothorax tubes
    - I used a Pole on the suction manifold in search of leaks and nothing ...


    Sometimes an ignition fall out of 1 cyl. I changed places with coils and candles and still falling out of 1cyl. But this error only appears sometimes


    Have any ideas ?
    Which groups should I log in to fsi?
    Video of engine work.
    [Film: ca5a30320f] https://filmy.elektroda.pl/16_1536784077.mp4 [/ film: ca5a30320f]
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  • #2 17437940
    spinacz
    Level 42  
    Posts: 8542
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    Buddy, how can you replace or replace the valve of the variable valve timing, I bet that either he fell or some crap is there.
    The valve is the one that extends to the right in the ignition coil harness line.
  • #3 17438306
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Hi, I suspected you too :) I even removed the lid from the chain to check if the 3 rings on the adjuster were damaged ... but they are all: / the valve was also dismantled and does not look bad. I will try to do some substitution.
  • #4 17438328
    spinacz
    Level 42  
    Posts: 8542
    Help: 1196
    Rate: 2621
    I had a fairy tale in my car and after replacing the valve.
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  • #5 17438355
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Did you have any mistake? Was the chain heard? Did you buy a drug? How much did you pay?:>
  • #6 17438590
    spinacz
    Level 42  
    Posts: 8542
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    Rate: 2621
    There was a timing synchronization error, I thought something with the chain or timing something was wrong, I had the car in an ASO.
    They changed the timing because I already had to check the chain and everything with it and it was perfectly on the locks. Last attempt and they replaced the valve and the car as new. The cost in the valve ASO is PLN 300 as I remember and PLN 100 replacement. You could hear the chain so that the first option even ASO that is something with tensioners or slides and turned out to be a valve.
  • #7 17438617
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    For me, only error from egr, the chain can not be heard even when firing: / but I will try to replace this valve.
  • #8 17442990
    spinacz
    Level 42  
    Posts: 8542
    Help: 1196
    Rate: 2621
    And how is the toy car?
  • #9 17443005
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
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    Tomorrow I will replace this stimulus setting. I tested it with Vag when it was dismantled and opened. During the week, I will probably dismantle the entire intake, etc. Suspected injection from 1 cylinder. When I was checking the spark, a large mist of fuel flew from 2,3,4 cylinders when I was turning the starter, and the 1cyl was slightly weaker.
  • #10 17450356
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Gentlemen, now I have ignition loss all the time. 1 I changed coils, I replaced candles on this Cyl. and nothing further: / VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation
  • #11 17453291
    lukasz12345678910
    Level 30  
    Posts: 1319
    Help: 173
    Rate: 483
    Swap the gasoline injectors now.
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  • #12 17472329
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Gentlemen, today I had some time and I dismantled the injectors and valve cover ... I saw such a view: / VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation

    I understand that this is the reason for unequal work? :) the fights are also torn on the boxes ... a bit strange that the engine was running quite quietly etc. The roller from the pusher is rough but not oval, and the cam on 1 cylinder is in better condition than the one in the photo. The photo cam looks very worn, but as if the contact surface with the roller has no level difference with the places where the roller does not touch (golden edges of the cam)

    Is this a direct cause of unequal work ?? Why is all this worn down? Oil pressure is supposed to be ... no messages about its absence: / unfortunately I have nothing to measure it physically.
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  • #13 17472453
    Don de Leon
    Level 24  
    Posts: 837
    Help: 51
    Rate: 458
    I met with something like this, the engine was rescheduled and previously lay under a cloud. But I've also heard of cases where oil was to blame.
  • #14 17472615
    lukasz12345678910
    Level 30  
    Posts: 1319
    Help: 173
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    Nothing special in newer VW, especially if someone observed the factory oil change intervals. But that's not the reason. Give these injectors to check.
  • #15 17472706
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Pusher from the first cylinder VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation

    However, it is round :) so it probably fulfills its function ...

    As for the injections, I already have them on the table and tomorrow I will try to check them by home methods (compressed air with the addition of fuel + 12v to open the coil), maybe you can find out more about their condition :) you can see that someone has fought hard with this engine: / because everything is stuck with silicone :) ) lid gasket + silicone, intake manifold gasket + silicone, INJECTIONS stuck onto silicone!
  • #16 17474671
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    I did such a test, I connected a piece of rubber hose with the injector and I preferred a little bit of WD40 + to it, I connected the compressed air :) I used about 11v to open the coil :) each injection, including what was in 1 cyl, spray a nice mist

    Short movie.
    https://youtu.be/zezLZqG_ftc
  • #17 17477943
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    I changed the injection of 1 out of 4 and the falling out error appeared on 4 cyl. I'm ordering an injector and I'll see what happens.
  • #18 17511942
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Gentlemen, I replaced the injector with another one that is working properly and no error from the ignition loss occurs :) even after a long ride :) but still jerks the engine like in the video. The only error that pops up from time to time is the probe 3 ... I will add that Passat is with the machine and it is uneven only on the P and N positions, if you throw it in "D" or anything that lightly loads the engine, you can hardly feel the vibrations. ..: / today I was putting the valve of the timing and EGR control valve in working order and 0 results: / where else to look?
  • #19 17534190
    niedzwiadek18
    Level 12  
    Posts: 236
    Help: 1
    Rate: 50
    Toy car repaired! It's perfect :) it didn't leave me alone :) I dismantled the fights, the chain and played a variator out of curiosity to see how it looks inside :) it turned out that there is something like a washer with a notch and a spring :) for me, the washer was wiped practically evenly and wedged in the hole in which it should work loosely (I compared the appearance of the center with the film on youtube) :) I bought a damaged variator, translated the washer and the engine works perfectly :) additionally, I cleaned the strainer which is between the head and the timing chain housing :)

    Comparison of washers VW Passat B6 2.0 FSI BVY Engine: Uneven Idle, EGR Error, Possible 3-Cylinder Operation
  • #20 20232262
    marcinmajsterek87
    Level 1  
    Posts: 1
    Rate: 1
    Hello,
    A great solution to the problem. I already bought a second car occasionally with the same symptom and no one knew what it was, and in both cases it was the same. One car is a Passat 2.0 FSI and the other is an Audi A6 TFSI. In both cases there are no errors in the computer. In the Audi, the car additionally kicked when firing. I will add a few of my comments. The key to unscrew the ZFR wheel is 10mm RIBE looks similar to the Torx, but you will not unscrew it. The screw is glued to the glue, so it is worth to heat it up and one quick move if not, it remains to drill (the screw is 12mm). When replacing the ZFR, always put in new rings 06F198107A but not those with all ... o because there they sell plastic crap that does not work because there is no gap on the perimeter, so when pressing, you will either break them or cut them short. Only original steel rings that have a gap of about 3mm on the circumference and compress when inserted. Every time I do this job, I replace the chain, the tensioner and, of course, the seal. In one of the openings from the housing there is a small filter that you should remove and clean.
    Tighten the ZFR screw by 20NM and add 45 degrees. Timing cover bolts 10Nm. A lock would be useful to set the shafts, but I did without it and it will also work with an 18mm wrench to move the fight and a morsel to lock. I hope to help someone.
  • #21 21497969
    michalwantulok8
    Level 2  
    Posts: 2
    >>17437636 hello I have the same problem 2,000 Euros have been added and the engine is still rattling, what helped was this phase valve

    >>17437636
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Topic summary

✨ A VW Passat B6 2.0 FSI (engine code BVY) exhibited uneven idle and an EGR-related error, with symptoms resembling three-cylinder operation at low RPMs. The EGR valve was disconnected due to water damage and corrosion but remained physically closed and tight. Compression tests showed 12 bar on all cylinders, and spark was confirmed on all spark plugs. Valves and carbon deposits had been cleaned, and vacuum lines replaced. Initial suspicion focused on the variable valve timing (VVT) valve, which was replaced after timing chain and adjuster inspection showed no damage. Ignition coil and spark plug replacements on cylinder 1 did not resolve misfire issues. Injector testing revealed proper spray patterns, but swapping injectors shifted misfire errors to other cylinders, indicating injector faults. Despite replacing faulty injectors, engine jerking persisted at idle and neutral but diminished under load. Further inspection uncovered significant camshaft and lifter wear, with a worn timing variator washer causing timing irregularities. Replacing the variator washer and cleaning the timing chain strainer restored smooth engine operation. Additional advice included careful replacement of timing chain components, especially the ZFR wheel and steel rings (part 06F198107A), avoiding plastic aftermarket parts. Similar symptoms were reported in Audi A6 TFSI engines without error codes. The discussion highlights the complexity of diagnosing uneven idle and misfire in VW 2.0 FSI engines, emphasizing the importance of timing variator condition, injector functionality, and EGR valve status.
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FAQ

TL;DR: BVY rough idle? Cam phaser (ZFR) service often fixes it; tighten 20 Nm + 45°, and "in both cases there are no errors". [Elektroda, marcinmajsterek87, post #20232262]

Why it matters: For Passat B6 BVY and Audi 2.0 FSI/TFSI owners chasing uneven idle or misfire, this gives the proven fixes, tools, and torques.

Quick-Facts

Quick Facts

What actually fixed the uneven idle in this BVY case?

The cam phaser (variator) internals were worn. A notched washer had jammed inside the ZFR. Swapping in a good washer from a donor phaser and cleaning the small strainer between the head and timing cover restored smooth idle. “It’s perfect” after reassembly. [Elektroda, niedzwiadek18, post #17534190]

How do I tell if an injector is the cause of a BVY misfire?

Swap the suspect injector with another cylinder and read misfire counters. Here, moving injector 1 to cylinder 4 moved the misfire to 4. That confirmed the injector as the fault. Replace the injector that follows the misfire. [Elektroda, niedzwiadek18, post #17477943]

Can a bad VVT solenoid cause rough idle, and what did it cost to fix?

Yes. One owner had a timing sync error and chain noise. After checks, the dealer replaced the VVT solenoid, and the car was “as new.” Reported costs were about PLN 300 for the valve and PLN 100 labor. [Elektroda, spinacz, post #17438590]

What torque and tool do I need for the BVY cam phaser (ZFR)?

Use a 10 mm RIBE bit. The ZFR bolt is glued, so apply heat before loosening. Tighten the new bolt to 20 Nm plus 45 degrees. Timing cover bolts tighten to 10 Nm. “The key to unscrew the ZFR wheel is 10mm RIBE.” [Elektroda, marcinmajsterek87, post #20232262]

Do I need to replace the cam phaser rings, and which ones?

Yes. Replace the ZFR sealing rings during service. Use kit 06F198107A with original steel rings. They have about a 3 mm gap and compress on installation. Avoid plastic copies that don’t compress or may crack. [Elektroda, marcinmajsterek87, post #20232262]

Is strong, even compression enough to rule out mechanical damage?

Not entirely. This BVY showed 12 bar on all cylinders, yet idle was still uneven. Even compression indicates base sealing but doesn’t isolate valvetrain or fueling faults. Further checks were required in this case. [Elektroda, niedzwiadek18, post #17437636]

Does disconnecting the EGR cause the engine to run poorly?

In this case, the EGR was physically closed and unplugged. The engine started normally and pulled well, but idle stayed uneven. The only fault code was for the unplugged EGR. That pointed elsewhere for the root cause. [Elektroda, niedzwiadek18, post #17437636]

What if there are no fault codes, yet the engine kicks at startup and idles rough?

ZFR phaser issues can present with no DTCs. A tech fixed two 2.0 FSI/TFSI cars with these symptoms by servicing the ZFR. “In both cases there are no errors.” Clean the small filter and renew rings. [Elektroda, marcinmajsterek87, post #20232262]

What else should I replace or clean during cam phaser service?

Replace the timing chain, tensioner, and seals while servicing the ZFR. Remove and clean the small filter located in the timing housing. Leaving debris risks repeat phaser problems after reassembly. [Elektroda, marcinmajsterek87, post #20232262]

Will chain noise always mean worn chain or guides on BVY?

No. One case had chain noise and a sync error, yet the timing was correct on locks. Replacing the VVT solenoid solved the issue without replacing chain hardware. [Elektroda, spinacz, post #17438590]

Which scan tool did users employ to test components?

VAG/VCDS was used to actuate the timing solenoid during bench testing. It also read the EGR fault when unplugged. This guided the next mechanical checks. [Elektroda, niedzwiadek18, post #17443005]

How did a user bench-test direct injectors at home?

He fed WD‑40 plus compressed air through a hose into each injector. He pulsed the coil with about 11 V to open it. Each injector produced a fine mist in this simple test. [Elektroda, niedzwiadek18, post #17474671]

How do I service the BVY cam phaser (ZFR) to cure idle shake?

Follow this:
  1. Lock camshafts; hold with an 18 mm wrench while securing.
  2. Heat the glued ZFR bolt; loosen with a 10 mm RIBE.
  3. Fit new steel rings (06F198107A), clean the small filter, then torque 20 Nm + 45°. “Tighten the ZFR screw by 20NM and add 45 degrees.” [Elektroda, marcinmajsterek87, post #20232262]
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