Replaced Turbo, Now Limp Mode...

[Anthony*1989]

Hi Guys!

So last week I noticed what sounded like a small whale under the bonnet. The car still seemed to drive and boost okay but I put the noise down to the turbo on its way out. Rather than buy a brand new unit from Garrett, I deviced to buy a cartridge from TurboRebuild. Anyway long story short after fitting the new cartridge into the compressor housing and fitting it all back onto the car, I am now getting limp mode on start up with Engine Management Light and also the coil plug light. I am getting the 2 following codes in VCDS

009573 - Turbocharger Boost Control Position Sensor Circuit
P2565 - 002 - Signal too High - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 2
Reset counter: 255
Mileage: 159705 km
Time Indication: 0
Date: 2017.06.27
Time: 18:55:02


Freeze Frame:
RPM: 0 /min
Torque: 0.0 Nm
Voltage: 11.40 V
Duty Cycle: 0.4 %
Duty Cycle: 21.7 %
Absolute Pres.: 979.2 mbar
Voltage: 0.000 V


004109 - Actuator for Turbocharger Adjustment
P100D - 000 - Stuck or Hard to Move - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Fault Frequency: 7
Reset counter: 255
Mileage: 159705 km
Time Indication: 0
Date: 2017.06.27
Time: 18:59:39


Freeze Frame:
RPM: 882 /min
Torque: 105.3 Nm
Temperature: 17.1°C
Duty Cycle: 95.5 %
Duty Cycle: 78.9 %
Duty Cycle: 100.6 %
Duty Cycle: 1.0 %


Readiness: 1 1 0 0 0


I ran a test on the VNT actuator using VCDS and can confirm it is moving, all the vanes in the turbo seemed to move fine before putting it back together and the lever moves fine with actuator arm disconnected. The VNT actuator wasn't removed when fitting the new cartridge - only the arm that connects it to the VNT Lever on the turbo. So as far as I can tell the VNT actuator shouldn't need calibrating. I'm really stuck and need some help...

Regards

Anthony

[Anthony*1989]

I'm thinking when removing the compressor housing... if I didn't bolt it up back in the exact position it came off from...this could be the cause?

[Anthony*1989]

no one with any experience on this?

[Rob69]

What do you mean it didn't bolt up in exact position it came off from - do you mean it is rotated to a slightly different position or the compressor volute housing didn't go back in the same axial position? Did this cartridge include a shaft and turbine wheel or just the bearing housing and bearings installed?