[Vwdiesel] [VW-TDI] Re: Need suggestions on which code to start troubleshooting.

[Dave Cook]

This reminded me that I don't think I ever posted the results of fiddling with the turbo on my friend's '01 Jetta.  We had been off and on working on the limp mode and overboost codes for a couple years.

I pulled the turbo and determined that the actuator was bad, as it didn't hold vacuum.  When I pulled it off, a bunch of rusty junk came out of the little breather hole.

I also determined that the VNT lever wasn't moving as far as it should.  I was never able to get the turbo open-I heated it, banged with hammers, sprayed with PB Blaster, and even tried the trick of melting wax into the gap but it never came loose.  


So eventually I was able to manually move the lever to break it free.  I sprayed some oven cleaner in there and worked the lever, let it sit, added more cleaner, worked the lever, etc etc until it was moving freely and easily. I then rinsed it out and put everything back together.

My friend told me a couple days later that once again he was in love with his car!

 
Dave Cook


________________________________
 From: fugazi48 <heltonbr at yahoo.com>
To: VW-TDI at yahoogroups.com 
Sent: Friday, July 20, 2012 8:08 AM
Subject: [VW-TDI] Re: Need suggestions on which code to start troubleshooting.
 

  
Thanks for the help. 

This is a 2003 with 220,000 miles. ALH I believe. 

I cleared the codes yesterday, and after 2 drive cycles, all but the boost code returned.  I usually only get weak acceleration(limp mode) when it is hot. Today was mild. 

I checked the EGR for carbon back in 2008, looked clean, so I never checked the intake for the buildup. 

The turbo actuator had failed in 2008 due to duty cycle.  The tech was able to get the VNT to swing again with a little play.  I am assumeing I may need to check the turbo again. 

I'll check the EGR this weekend, see if the valves actuate.  Inspect the wiring.  I will take photos in case it helps others. 

Thanks. 

--- In VW-TDI at yahoogroups.com, Tad <thadddeus at ...> wrote:
>
> Assuming this is an ALH engine, this is consistent with intake clogging
> plus a bad GP harness... except for  19560/P3104/012548 - Valve for Intake
> Manifold Flap (N239): Short to Plus... not sure what to make of that.
> 
> On Thu, Jul 19, 2012 at 10:42 AM, fugazi48 <heltonbr at ...> wrote:
> 
> > **
> >
> >
> > I had been ignoring a lamp for loose glow plug harness for a while.
> >
> > Been experiencing turbo whine and occasional loss of power. Decided to
> > plug in my code reader.
> >
> > Received this list.
> > 16618/P0234/000564 - Boost Pressure Regulation: Limit Exceeded (Overboost
> > Condition)
> > 17055/P0671/001649 - Cylinder 1 Glow Plug Circuit (Q10): Electrical Fault
> > 17058/P0674/001652 - Cylinder 4 Glow Plug Circuit (Q13): Electrical Fault
> > 16785/P0401/001025 - Exhaust Gas Recirculation (EGR) System: Insufficient
> > Flow De
> > 19560/P3104/012548 - Valve for Intake Manifold Flap (N239): Short to Plus
> > ==
> > 17057/P0673/001651 - Cylinder 3 Glow Plug Circuit (Q12): Electrical Fault
> >
> > Since EGR is on top, and leaking oil, I thought i would clean it up , and
> > check if first. Any other suggestions?
> >
> > I am not sure what the intake flap even looks like.
> >
> > Thanks for any suggestions.
> >
> > 
> >
> 
> 
> [Non-text portions of this message have been removed]
>


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