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Discussion Starter #1 (Edited by Moderator)
Hi all I recently installed a new turbo to my 1.9 TDI 77kw BJB engine, it bogs down really hard with loads of black smoke until it hits 2500rpm then is good until gear change drops it below 2500 then it bogs down again, I've since removed the vacuum running to the actuator were at least I can drive it but am keen to sort this issue out, I got a vacuum pump and the rod starts moving after 5hg and stops at 17 which seems correct, what else could it be .
thanks...


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I thought you had a Toledo we have a Seat/Skoda sub forum?

This stupid new site does show car spec.

This is a new forum layout with loads of bugs which have been reported in the new thread. There is no TDI Wiki at the moment or or original similes. It doesn't show the car spec/location or signature properly either

We Are Live - Community Feedback

I can't move this thread.

Manufacturer: Seat, Date(s) Used: 09/2004-09/2005, Model: Toledo, Engine Code: BJB, 77Kw, 105PS, 1.9 Ltr, 4 Cyls, Remarks: Turbocharged Direct Injection Pumpe Düse (TDI-PD), 8v Timing belt

You need to get your motor scanned (preferably with VAG-COM\VCDS) for any error codes logged in the ecu and post them, that will save a lot of guessing and check systems out.
 

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Discussion Starter #3 (Edited)
hi keith ive scanned the car with the following errors,ive readjusted the vnt leaver both ways without any success ..
ive disconnected the egr vacuum and pluged it
i havnt disconnect the asv as yet
it is a vw caddy 1.9tdi 77kw bjb engine
here is the scan results
Address 01: Engine Labels: 03G-906-016-BKC.clb
Part No SW: 03G 906 016 DM HW: 028 101 188 2
Component: R4 1,9L EDC G000SG 6045
Revision: 12345678 Serial number: VWZ7Z0D1100582
Coding: 0050071
Shop #: WSC 35110 377 00161
VCID: 71E9241B68246AC916-8024

2 Faults Found:
16785 - EGR System
P0401 - 000 - Insufficient Flow
Freeze Frame:
RPM: 1449 /min
Torque: 36.0 Nm
Speed: 62.0 km/h
Load: 12.2 %
Duty Cycle: 14.7 %
Bin. Bits: 00001000
Mass Air / Rev.: 220.0 mg/str
Mass Air / Rev.: 505.0 mg/str

16683 - Boost Pressure Regulation
P0299 - 000 - Control Range Not Reached
Freeze Frame:
 

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Ok your talking about a Caddy. I've changed the title. ;)

Manufacturer: VW, Date(s) Used: 05/2008-08/2010, Model: Caddy, Engine Code: BJB, 77Kw, 105PS, 1.9 Ltr, 4 Cyls, Remarks: Turbocharged Direct Injection Pumpe Düse (TDI-PD), 8v Timing belt

VAG Error Code: 16785/001025/4807/7337

EOBD II Error Code: P0401

Fault Location:
Exhaust Gas Recirculation (EGR) System - Insufficient Flow Detected

Possible Cause:
Malfunction Indicator Lamp (MIL)(K83) active.
Reduced Exhaust Gas Recirculation (EGR).
Reduced Power Output/Engine running rough.
Increased Emissions.

Wiring/Connector(s).
Hose leak/blockage.
Exhaust Gas Recirculation (EGR) Flow restricted/clogged.
Exhaust Gas Recirculation (EGR) Valve stuck closed/leaking/faulty.
Exhaust Gas Recirculation (EGR) System faulty.

Possible Solutions:
Check/Replace all faulty Wiring/Connector(s).
Check/Clean Exhaust Gas Recirculation (EGR) System.
Read Measuring Value Blocks (MVB).
Check/Replace Exhaust Gas Recirculation (EGR) Valve.
Control deviation < limit from map f (engine speed, desired airflow).

Special Notes:
When this fault is stored in a 2009-2012 North American Region (NAR) market 2.0L CR TDI (CBEA, CJAA, CKRA) VW Jetta/Golf (1K/AJ) or the NMS Passat (A3) chassis:
Please see: Technical Service Bulletin (TSB) 26-13-03 | Technical Product Information (TPI) #2031583/3 (formerly know as 26-12-08 | Technical Product Information (TPI) #2031583). When the Exhaust Valve Control Module (J883) is faulty, the engine controller may have any of the following Diagnostic Trouble Codes (DTCs):
P046F, P0477, P048A, P048B, P048C, P0401.
Some TDI-CR engines have a filter for the Exhaust Gas Recirculation (EGR) that can become restricted and cause a "Insufficient Flow" code.

When this fault is stored in a 2009-2014 North American Region (NAR) market 2.0L CR TDI (CBEA or CJAA ) VW Jetta/Golf (1K/AJ).
Please See Technical Product Information (TPI) 01 14 11 | #2034898
May also have fault code stored in Engine Control Module (ECM).
009315/P2463/009315 - Diesel Particulate Filter (DPF) - Excessive Soot Accumulation.
Restrictions in the Exhaust Gas Recirculation (EGR) Filter may occur after a regeneration, if the soot loads where high before the regeneration.

Tech Notes:
Exhaust Gas Recirculation (EGR) flow malfunction could be caused by a clogged Exhaust Gas Recirculation (EGR) valve or Exhaust Gas Recirculation (EGR) tube. Before replacing any parts try cleaning the Exhaust Gas Recirculation (EGR) valve, tube and passages.

When is the code detected?:
Restrictions in the EGR Filter may occur after a regeneration, if the soot loads where high before the regeneration.

VAG Error Code: 16683/15343/15343/14914/11226/12896/7384/5171/5671/000665

EOBD II Error Code: P0299

Fault Location:
Boost Pressure Regulation - Control Range Not Reached/Low Boost

Possible Cause:
Malfunction Indicator Lamp (MIL)(K83) active.
Reduced Power Output.
Limp Mode.
Limp mode: What is it, what are the causes, and how to fix it for the Audi and VW TDI diesel turbo.

Hoses/Pipes incorrectly connected, disconnected or leaking.
Charger Pressure Control defective.
Turbocharger faulty.
Diverter Valve faulty.

Possible Solutions:
Check Hoses/Pipes to/between Components.
Check/Clean/Replace Charge Pressure Control.
Check Turbocharger.
Check Diverter Valve.

Special Notes:
If the Turbocharger is faulty due to mechanical/internal problems or the exhaust system is restricted (typically the Catalyst) this fault may be the end result.

Gasoline:
When found in 2.0l TFSI:
Check Boost Pressure Control Valve (N249) (Turbocharger Recirculating Valve) for cracked rubber diaphragm. A new/optimized Valve is available under Part # 06H-145-710-D (or newer).
Rest of World (RoW) vehicles see: Technical Product Information (TPI) 2016331 for details.
North American Region (NAR) vehicles see: Technical Service Bulletin (TSB) 01-07-70 or 2013392 for details.
When stored in conjunction with misfire codes and/or fuel trim faults see the notes associated with the following faults regarding Positive Crankcase Ventilation (PCV) failure: Crankcase Breather Valve
When found in Audi A4/S4/RS4/Cabriolet (8K): 2.0l (CAEB):
See Technical Product Information (TPI) 2031245/6 - turbocharger excessive waste-gate play.

Diesel:
When found in VW Golf/Jetta (1K): 2.0l CR-TDI (CBEA/CJAA):
Verify the mechanical part of the Exhaust Valve Control Module (J883) is not seized or binding.
When found in the 1.9 L TDI-PD (BLS):
Check vacuum supply from the vacuum reservoir located in the valve cover for leaks. Using a vacuum gauge, wiggle the valve cover and hose connections to check for a leak. The following photo was submitted from a customer working on a 2010 VW Caddy (2K chassis) with this vacuum reservoir problem.





As taken from my new Free EOBD II Error Codes software
 

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Discussion Starter #5
Hi all so I removed the turbo yesterday,I reset the stop screw so the vanes were not totally closed,now the actuator arm does not have the same travel and while using my vacuum pump I Only get to 12hg before it's at its limit of movement ,the actuator is also very easy to push the rod in ,does it sound like I may need a new actuator at all...


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Discussion Starter #8
For those who are interested it was the vnt vanes closed fully ,I removed the turbo and reset them,and adjusted the actuator length as well ,all good now,drives like a new van...

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