Golf Mk5 2009 2.0 diesel

Car info:

Golf estate 2009 (58)
2.0 140bhp diesel engine
Engine code (CBD)

Symptoms

Low revs up to 2k care drives fine
over 2k black smoke and occasionally stutters
no power over 2k rpm
No fault codes using my delphi dsc150
my vagcom 409 does not connect
Turbo whistle only slightly but every turbo diesel i have owned does it

Things i have done

Checked the actuator moves freely by moving it with vacuum tank not being mounted to the turbo (which it does)
put a vacuum pump on the actuator and tested (it does move but only half inch possible an inch)
disconnected dpf/cat and spray mr muscle in back end of the turbo
shaft has a little play but spins smoothly and freely
disconnets maf (no difference)
changed air filter

has anyone got any ideas before i replace the turbo

The shaft shouldn't have noticeable play only end float, smoking with power loss all spell turbo issues if disconnecting it changes nothing then it's likely to be the issue get it checked before it go's properly and takes out the engine as well.

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Cheers, im going to test boost pipes and vacuum lines tomorrow

Quote:

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Originally Posted by mgs41987

Cheers, im going to test boost pipes and vacuum lines tomorrow

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just and update, did a pressure test and yes the boost pipe was faulty, the pipework was coming out of the aluminium moldings and someone had put a screw through it to stop it blowing off, so that has been rectified but issue carried on

Attachment 35145

turns out the shaft on the egr cooler actuator has snapped, and the vacuum line had split and the diaphragm was leaking , now capped vacuum line as it turns our it has been remapped so the egr system is obsolete so i capped the vacuum line to it and all them problems have been rectified,

Attachment 35146

the car has loads of power back but getting new codes

P2563 OBD-II Trouble Code: Turbocharger Boost Control Position Sensor Circuit Range/Performance

i have replaced the turbo so it must be electrical or sensor related

anyone have any ideas

Right all sorted now

N75 valve was getting faulty after the engine hit operating temp, now replaced.

The smart actuator was infact faulty, i had to prove it by taking new turbo off, putting original back on, driving it and seeing if fault appeared. after fault was not appearing i sent the new turbo back, they replaced and reset the actuator etc and now it is back on the car no faults appearing. drove it for 40 miles and its perfect

also along the way, when taking the old turbo off for the second time the oil feed was binding and it started to kink. to replace it VW wanted £75 + vat for the pipe, didnt want second hand one, and aftermarket i couldnt get quick enough but also fitting it was going to be a C**t. i chopped it out and made one out of flex and braided, same internal diameter and now it runs for filter up over the top but almost against the intake pipework. 800mm length with a elbow at the end for anyone wanting to know and it cost £15.


so the things wrong with it

oil pressure sensor decayed
Boost pipe coming out the castings
oil feed kinked (even though in ideal world need to be replaced everytime)
vacuum pipe on egr divertor split
actuator shaft for egr cooler snapped
egr cooler actuator not holding vacuum
turbo F*****d
new turbo smart actuator faulty

Be careful that the temperature rating of the new pipe is suitable- should be about 150 deg to be on the safe side. A lot of braided hoses are intended only for low temp brake lines.

its rated for industrial equipment

What does "rated for industrial equipment" mean ? If it was my car I would need to know what the specific temp rating was.