Hi guys, I've been having problems with my 2002 1.9 Tdi (PD, engine code ARL).
I've replaced the turbo (old one had leaking seals & left a fair bit of oil in pipes & intercooler) & just had a new camshaft & timing belt fitted (as old ones had turned to chocolate!) & head removed & skimmed.
I've got an EGR delete & have removed ALL the vacuum piping from the anti-shudder & EGR valve.
I've also replaced the vacuum tubing from the N75 to the turbo & to the accumulator & vacuum source- (that's the only vacuum tubing I have now)
I also swapped around the N75 valve & the one next to it.
The garage confirmed that it holds a vacuum OK & the turbo actuator moves fine - also checked with VCDS.
I've replaced the MAF too.
I've been having the 17964 code & limp mode whilst under load - if I thrash the car through the gears then it seems OK, if I put it into 4th early & just hold my foot to the floor, it goes into limp mode every time.
I'm now thinking about doing a boost leak check (when I replaced the turbo, I visually checked all the pipes etc & all seemed OK!) although I'm not getting any black smoke out when I accelerate (as I've been told I would with a boost leak).
On a diesel, should I block off after the EGR delete (where it goes into the intake) & pressurise from just after the MAF or should I let the pressurised air into the block & see what happens?
Assuming it shows no leak, my next plan of attack will be :
* MAP / temp sensor (no code shown though)
* Possibly a blocked CAT?
* Tandem pump (putting out enough diesel pressure?)
* Check / replace the injector loom
* Is new turbo screwed already - does the VNT actuator need major adjustment??
Earlier yesterday, I fitted a new MAF (as old one was 4 years old anyway) & went for a drive & logged the info...
- 1st run was in 3rd from around 1500rpm & it didn't drop into limp mode.
2nd run in 4th gear did go into limp mode....
This problem has only happened since I replaced the turbo - before that, it hadn't ever dropped into limp mode, so I guess it's something I've done but I have no idea what it can be!
The only vacuum tubing I've got is from the vacuum source to the N75, from the N75 to the turbo & N75 to the air box. There are no other lines (I've blocked off the one to the accumulator (ball) as the ball is leaking slightly).
I've done the output test on the n75 & it seems OK - I could see the actuator moving with no problems (it is a new turbo after all).
This is the engine data with it turned off:
and with it at idle :
This is the 1st run, 3rd gear from around 1500rpm & it didn't drop into limp mode:
and this is the raw data from this run :
This is the 2nd run, from 1500rpm in 4th gear which DID drop into limp mode (again) :
and this is the raw data :
MAP - I haven't touched & it looks like it hasn't been off the pipe that goes from intercooler to EGR delete in years - screws all rusted up...
Airfilter I actually removed for the 2 runs as it got wet
Turbo actuator not loose either.
Have just been out & taken off the hoses (& the pancake tubing) either side of the intercooler & checked again for leaks & replaced a couple of the green seals too.
All seemed fine (yet to do a boost leak check as I need to make the leak detector!)
FWIW, it was run for years with (by the look of it) a cheap ebay type tune up device which went between the feed to the injectors.
I took it off a few years ago when I had the turbo & camshaft replaced the 1st time (4yrs ago).
It started smoking (whiteish smoke) on startup & when booting it hence I replaced the turbo (quite a lot of oil in the intercooler pipework but I haven't been able to remove the intercooler itself to completely clean it but pipes are cleanish).
When I was doing the turbo, I checked the cam & followers & they looked like they were on the way out again so I had them replaced along with having the timing belt done.
The garage said one of the head bolts was loose (jesus) so they took the head off & had it skimmed as the head gasket looked slightly iffy.
Anyone got any ideas at all? (and sorry for length of post but hopefully there's enough info!0
Many thanks for any help with this poxy problem!!
I've replaced the turbo (old one had leaking seals & left a fair bit of oil in pipes & intercooler) & just had a new camshaft & timing belt fitted (as old ones had turned to chocolate!) & head removed & skimmed.
I've got an EGR delete & have removed ALL the vacuum piping from the anti-shudder & EGR valve.
I've also replaced the vacuum tubing from the N75 to the turbo & to the accumulator & vacuum source- (that's the only vacuum tubing I have now)
I also swapped around the N75 valve & the one next to it.
The garage confirmed that it holds a vacuum OK & the turbo actuator moves fine - also checked with VCDS.
I've replaced the MAF too.
I've been having the 17964 code & limp mode whilst under load - if I thrash the car through the gears then it seems OK, if I put it into 4th early & just hold my foot to the floor, it goes into limp mode every time.
I'm now thinking about doing a boost leak check (when I replaced the turbo, I visually checked all the pipes etc & all seemed OK!) although I'm not getting any black smoke out when I accelerate (as I've been told I would with a boost leak).
On a diesel, should I block off after the EGR delete (where it goes into the intake) & pressurise from just after the MAF or should I let the pressurised air into the block & see what happens?
Assuming it shows no leak, my next plan of attack will be :
* MAP / temp sensor (no code shown though)
* Possibly a blocked CAT?
* Tandem pump (putting out enough diesel pressure?)
* Check / replace the injector loom
* Is new turbo screwed already - does the VNT actuator need major adjustment??
Earlier yesterday, I fitted a new MAF (as old one was 4 years old anyway) & went for a drive & logged the info...
- 1st run was in 3rd from around 1500rpm & it didn't drop into limp mode.
2nd run in 4th gear did go into limp mode....
This problem has only happened since I replaced the turbo - before that, it hadn't ever dropped into limp mode, so I guess it's something I've done but I have no idea what it can be!
The only vacuum tubing I've got is from the vacuum source to the N75, from the N75 to the turbo & N75 to the air box. There are no other lines (I've blocked off the one to the accumulator (ball) as the ball is leaking slightly).
I've done the output test on the n75 & it seems OK - I could see the actuator moving with no problems (it is a new turbo after all).
This is the engine data with it turned off:

and with it at idle :

This is the 1st run, 3rd gear from around 1500rpm & it didn't drop into limp mode:

and this is the raw data from this run :

This is the 2nd run, from 1500rpm in 4th gear which DID drop into limp mode (again) :

and this is the raw data :

MAP - I haven't touched & it looks like it hasn't been off the pipe that goes from intercooler to EGR delete in years - screws all rusted up...
Airfilter I actually removed for the 2 runs as it got wet
Turbo actuator not loose either.
Have just been out & taken off the hoses (& the pancake tubing) either side of the intercooler & checked again for leaks & replaced a couple of the green seals too.
All seemed fine (yet to do a boost leak check as I need to make the leak detector!)
FWIW, it was run for years with (by the look of it) a cheap ebay type tune up device which went between the feed to the injectors.
I took it off a few years ago when I had the turbo & camshaft replaced the 1st time (4yrs ago).
It started smoking (whiteish smoke) on startup & when booting it hence I replaced the turbo (quite a lot of oil in the intercooler pipework but I haven't been able to remove the intercooler itself to completely clean it but pipes are cleanish).
When I was doing the turbo, I checked the cam & followers & they looked like they were on the way out again so I had them replaced along with having the timing belt done.
The garage said one of the head bolts was loose (jesus) so they took the head off & had it skimmed as the head gasket looked slightly iffy.
Anyone got any ideas at all? (and sorry for length of post but hopefully there's enough info!0
Many thanks for any help with this poxy problem!!