Help Please!

[NeilB1970]

Thanks for having me on the forum, I will try to keep it short and sweet, having been quite happy with my 2.0tdi passat for the last 5 years and having relatively no issues with it other than it having 230k on it, I started to look for a replacement vehicle to tow and launch my boat, I wanted a 2.oL for the economy but something a little higher off the ground and 4x4, after some research I found that Mitsubishi outlanders had a 2.0 VW engine in them, I gave my son the passat and purchased an Outlander at Auction with 64k on the clock, I had it delivered as I lived a good way away from the Auctions, driving it for its MOT about 5 miles later the head gasket blew on the motorway at 70 mph :aargh4::aargh4::aargh4::aargh4::aargh4::aargh4::a argh4::aargh4:, as I had no comebacks against the Action or the garage selling it I was advised to purchase a low mileage secondhand engine as there was a possibility that there was additional damage to the engine, I had it fitted only to discover that the Turbo was passing oil :aargh4::aargh4::aargh4::aargh4::aargh4::aargh4::a argh4::aargh4::aargh4::aargh4::aargh4::aargh4::aar gh4::aargh4::aargh4::aargh4::aargh4::aargh4::aargh 4::aargh4:, I took it to a local garage and £610 later I have a car that goes into limp mode with ECU codes P0234 (Turbo over boost) and P0401 (Exhaust Gas Re circulation inadequate), speaking to the mechanic he feels that either the pipes have been crossed or the vac box is faulty, he has blocked the vac pipe to the EGR(hence the EGR code) as he feels it was getting Vac at the wrong time, has anyone got a vac pipe diagram for the BSY engine so I can rule this out, also any advice (other than scrap it lol ) would be much appreciated
Thanks in advance,

Neil

[Rob69]

Hi
That's a bit of a sorry tale ! did they fit a recon turbo for the 600 quid or a used one? here's a diagram for an octavia but i suspect the valve blocks are the same layout across the engine ranges, could be wrong though - sorry if that's not much help, I was going to suggest getting someone to hook up VCDS but I doubt if it would connect to the mitsubishi
Engine with identification characters BKC, BXE (http://workshop-manuals.com/skoda/octavia-mk2/drive_unit/1.9/77_kw_tdi_pd_engine/exhaust_turbocharger_g-charger/charge-air_system_with_exhaust_gas_turbocharger_part_1/connection_diagram_for_vacuum_hoses_(octavia_ii)/engine_with_identification_characters_bkc_bxe/)

[NeilB1970]

Hi Rob,
Thanks for the diagram I will have a look in the daylight tomorrow, the £610 was mine reconditioned and refitted, new bearings and seals, it was leaking oil through the inter cooler and coming up through the flap below the egr, the guy at the garage says because it is a VW engine but Mitsubishi brain it gives you limited information on his reader

[Rob69]

I've no idea what you would use to do any in depth diagnostics on that combination, hopefully it is a mix up of vacuum pipes on the block. Overboost can be down to sticking VNT vanes but since the turbo has been overhauled, shouldn't be that.

[NeilB1970]

Hi Rob had a look at the pipework on mine assuming that from the diagram P1,2&3 are on the left, top right is blanked off on mine P4,5&6 are the 3 remaining ones on the right,
1 goes to the t piece on the tandem pump on the engine,
2 disappears towards the turbo behind the engine,
3 goes to the electrically operated flap below the egr,
4 goes to the egr valve,
5 goes to the air filter housing,
6 disappears towards the turbo behind the engine,
so only P3 appears to be the same

[Rob69]

I can't confirm if that skoda 1.9 valve block diagram would be the same for your 2 litre, but I would think the valve blocks are the same across the engine ranges ?? maybe someone with the 2 litre engine can check and verify.
If the block is the same then some of your plumbing is incorrect!

[NeilB1970]

Thanks Rob hopefully someone can confirm

[NeilB1970]

I went in work today on a different shift and one of the lads on the shift has a 2.0l outlander;) checked the pipework on his vacuum system and it appears the same!!!!! removed the blanking plug the mechanic had put in the vacuum pipe for the egr valve............ thick white smoke came out of the exhaust, engine coughed and spluttered and cut out within 5 seconds, removed the pipe from the egr to put the blank back in there was a pop, so is holding vacuum, placed blank back in vac pipe and engine runs???????? anyone any ideas
Cheers

Neil

[Rob69]

So his vac pipes are set up the same as yours, progress!. Has yours got a vacuum operated anti shudder valve or an electric asv/ intake throttle flap upstream (below) of the vacuum egr valve. For the engine to kick out white smoke and die in seconds sounds like tĺhe asv was closed and not the egr valve. If you have the electric asv / throttle flap this could be throttling in trying to regulate the egr flow and your connecting the egr back up while running has freaked out the ecu and asv and choked off the intake air. In your post #5 (http://www.vwaudiforum.co.uk/forum/usertag.php?do=list&action=hash&hash=5) you say one vac pipe number 3 goes to the asv , maybe this operates the anti shudder flap, or is operated in tandem with the egr via the valve block. I've had to change a few of these electric asv / throttle flaps on 1.9 engines, but dont recall having any vac pipes connected to them. Sorry if thats confused things even more!

[NeilB1970]

Rob, will have a look tomorrow to confirm, it deffo has an electronic intake throttle flap not sure if it has a vacuum pipe as well but presumed that's where it went but if the flap was closed would it not happen all the time?

[Rob69]

The flap throttles intake air at low engine load to help create an intake depression draw in the exhaust from the egr valve, it also closes completely for several seconds when you turn the ignition off to give smooth run down or 'anti shudder' it is also a safety shut off device in case of engine running away. I think youll find there is no vac pipe attached. If your egr is blanked off at the vac hose but not deleted from the ecu, this flap will possibly be trying to control non existant exhaust gas supply.it will not be closed completely when running but when you suddenly reconnected the egr it could have been trying to control it and choked the engine, hence white smoke , These flaps are also prone to fouling up and the plastic gears strip.