Limp Mode

[fmc51]

Hello Folks,

My trusty 2.7 tdi quattro avant is getting on... (there is over 300,000 kilometers on it.)

Recently it is going into limp mode, especially when I accelerate, and the faults below are coming up on scan. It seems to hesitate, and then go. I replaced the Throttle valve recently, and both swirl flap assemblies, and the EGR valve. I am concerned that it may be the Turbo. (I put a new Turbo in in 2010, and I opened the old one the other day and found the vanes on the exhaust side had worn itself against the variable thingies, so bearing failure probably)

I don't think the glow plug faults are significant.

I am wondering if anyone can point me in the right direction?

               Address 01: Engine       Labels: Redir Fail!
Control Module Part Number: 4F2 910 401 P    HW: 4F0 907 401 B
  Component and/or Version: 2.7L V6TDI  G000AG  0010
           Software Coding: 0011372
            Work Shop Code: WSC 02334 785 00200
                      VCID: 2B55E1278AF0EB4608F-807E
6 Faults Found:


005659 - Glowplug for Cylinder 2 (Q11) 
               P161B - 001 - Open Circuit
             Freeze Frame:
                    Fault Status: 01110001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 303554 km
                    Time Indication: 0
                    Date: 2014.05.25
                    Time: 12:52:22


             Freeze Frame:
                    RPM: 819 /min
                    Torque: 46.8 Nm
                    Speed: 0.0 km/h
                    Duty Cycle: 1.0 %
                    Voltage: 13.68 V
                    Duty Cycle: 24.9 %
                    Temperature: 31.5°C


005662 - Glowplug for Cylinder 5 (Q15) 
               P161E - 001 - Open Circuit
             Freeze Frame:
                    Fault Status: 01110001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 303554 km
                    Time Indication: 0
                    Date: 2014.05.25
                    Time: 12:52:22


             Freeze Frame:
                    RPM: 819 /min
                    Torque: 46.8 Nm
                    Speed: 0.0 km/h
                    Duty Cycle: 1.0 %
                    Voltage: 13.68 V
                    Duty Cycle: 24.9 %
                    Temperature: 31.5°C


005663 - Glowplug for Cylinder 6 (Q15) 
               P161F - 001 - Open Circuit
             Freeze Frame:
                    Fault Status: 01110001
                    Fault Priority: 0
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 303554 km
                    Time Indication: 0
                    Date: 2014.05.25
                    Time: 12:52:22


             Freeze Frame:
                    RPM: 819 /min
                    Torque: 46.8 Nm
                    Speed: 0.0 km/h
                    Duty Cycle: 1.0 %
                    Voltage: 13.68 V
                    Duty Cycle: 24.9 %
                    Temperature: 31.5°C


013128 - Control Circuit for Controller for Turbocharger 1 (J724) 
               P3348 - 005 - Electrical Malfunction - Intermittent
             Freeze Frame:
                    Fault Status: 00100101
                    Fault Priority: 0
                    Fault Frequency: 11
                    Reset counter: 255
                    Mileage: 303574 km
                    Time Indication: 0
                    Date: 2014.05.26
                    Time: 08:21:13


             Freeze Frame:
                    RPM: 1344 /min
                    Torque: 117.0 Nm
                    Speed: 32.5 km/h
                    Temperature: 19.8°C
                    Duty Cycle: 78.9 %
                    Voltage: 13.76 V
                    Duty Cycle: 12.6 %


012696 - Control Circuit for Intake Manifold Runner (Bank1) 
               P3198 - 002 - Implausible Signal - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 0
                    Fault Frequency: 4
                    Reset counter: 255
                    Time Indication: 0


             Freeze Frame:
                    RPM: 168 /min
                    Torque: 210.6 Nm
                    Speed: 0.0 km/h
                    Voltage: 10.41 V
                    Duty Cycle: 0.4 %
                    Duty Cycle: 84.8 %
                    Duty Cycle: 80.9 %


000565 - Boost Pressure 
               P0235 - 001 - Regulation Range not Reached - Intermittent
             Freeze Frame:
                    Fault Status: 00110001
                    Fault Priority: 0
                    Fault Frequency: 8
                    Reset counter: 255
                    Mileage: 303776 km
                    Time Indication: 0
                    Date: 2014.05.27
                    Time: 12:48:33


             Freeze Frame:
                    RPM: 2856 /min
                    Torque: 230.1 Nm
                    Speed: 71.7 km/h
                    Absolute Pres.: 1662.6 mbar
                    Absolute Pres.: 1183.2 mbar
                    Mass Air / Rev.: 540.5 mg/str
                    Temperature: 20.7°C




Readiness: 0 0 0 0 0

[Guest 2]

Glowplugs aren't important but these ones are;

013128 - Control Circuit for Controller for Turbocharger 1 (J724)
P3348 - 005 - Electrical Malfunction - Intermittent
Freeze Frame:
Fault Status: 00100101
Fault Priority: 0
Fault Frequency: 11
Reset counter: 255
Mileage: 303574 km
Time Indication: 0
Date: 2014.05.26
Time: 08:21:13


Freeze Frame:
RPM: 1344 /min
Torque: 117.0 Nm
Speed: 32.5 km/h
Temperature: 19.8°C
Duty Cycle: 78.9 %
Voltage: 13.76 V
Duty Cycle: 12.6 %


012696 - Control Circuit for Intake Manifold Runner (Bank1)
P3198 - 002 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 4
Reset counter: 255
Time Indication: 0


Freeze Frame:
RPM: 168 /min
Torque: 210.6 Nm
Speed: 0.0 km/h
Voltage: 10.41 V
Duty Cycle: 0.4 %
Duty Cycle: 84.8 %
Duty Cycle: 80.9 %


000565 - Boost Pressure
P0235 - 001 - Regulation Range not Reached - Intermittent
Freeze Frame:
Fault Status: 00110001
Fault Priority: 0
Fault Frequency: 8
Reset counter: 255
Mileage: 303776 km
Time Indication: 0
Date: 2014.05.27
Time: 12:48:33


Freeze Frame:
RPM: 2856 /min
Torque: 230.1 Nm
Speed: 71.7 km/h
Absolute Pres.: 1662.6 mbar
Absolute Pres.: 1183.2 mbar
Mass Air / Rev.: 540.5 mg/str
Temperature: 20.7°C




Readiness: 0 0 0 0 0

Read and digest, maybe do a search for your codes on the forum too for previous fixes;

19804/P3348/013128 - Ross-Tech Wiki

16619/P0235/000565 - Ross-Tech Wiki

[colinrea]

could be just the variable turbo sticking the most probable cause is it is all gunked up with soot/carbon and will need a turbo clean on the exhaust side releasing the variable fins within the turbo, you can check the actuator to see if it is stiff or sticking in certain places, if it is intermittant then most likely sticking or stiff, had this on my 3.0 tdi quattro until I did a Mr Muscle clean and now as good as gold even after 6 months, it is a common problem on variable turbo diesels.

[fmc51]

Thanks for that,

can I ask how did you check the actuator for free movement. Did you check it in situ? Also, hoe did you clean the variable fins?

Regards

fergus

[colinrea]

Thanks for that,

can I ask how did you check the actuator for free movement. Did you check it in situ? Also, hoe did you clean the variable fins?

Regards

fergus

If it is the same as mine then the turbo is at the back of the engine on the top, the air pipe goes into the turbo from the airfilter and next to this there is an actuator with a lever attached to the turbo with ignition off you should be able to push the pushrod back/down and should return back up, there should be no resistance apart from the ecectric motor that controls it you can here the gears whirl inside the housing, you don't need to remove anything I suggest a flat screwdriver to push as you cannot get your fingers in and might be HOT, if its not smooth then either the turbo is sticking or actuator then you will need further investigation, hope this helps

[colinrea]

If you find that the turbo is stiff or sticking in certain places then most likely the vanes in the turbo are carbonised, if you go down the road of Mr Muscle then the engine must be cold totally not even warm. You will need a torx bit to remove the heatshield off the top of the turbo 2 on top and 1 on the right side low down the fiddley bit is removing the heatshield because of the pipes but can be done, then you can easily get to the sensor on the exhaust pipe for the RH bank of cylinders, remove this sensor will be tight.

Must stress you must wear gloves due to the caustic in Mr Muscle The Mr Muscle should be oven cleaner foaming version, you will need to attach a flexable hose to the nozzle (fish tank piping the best about 1 or 1.5 mtrs) once pipe attached squirt through the pipe to check that it is coming through, then feed the pipe through the hole and up to the turbo until it stops approx about 2 feet then squirt the foam in until it comes out of the hole, now leave for about 10 minutes then activate the lever every 5 minutes for about an hour this allows the caustic to breakdown the carbon once the tightness as gone then it as done its job. then fit the sensor back into the exhaust and start the engine and give it a good rev once or twice there will loads of black soot blown out of the exhausts dont worry this normal and it wont damage anything the Mr Muscle would be burnt off straight away stop the engine now refit the heatshield and then take the car for a quick spin and all done all in all about 2 hours but this does depend how bad the vanes have carbonised, if the turbo is ok then you may be looking at the atcuator, controller, pressure sensor and the list goes on.

Hope this helps

[fmc51]

THanks for your help... I'll have a go at it later. Fergus