P0299 - 006 - ControlRange Not Reached - Intermittent

[nick.king]

**APOLOGIES for posting this twice, I replied to a post in the wrong section initially, I didn't realise until now**

Afternoon guys,

I had this issue on the 24th July on the M1, was just over-taking a car at about 65-70 then there was a sudden jolt, my foot was flat to the floor and I had no power. Moved over to the left lane and noticed the glow plug light was flashing, I didn't hear a bing as I had the windows down (air con needs a regas!), the stretch of M1 I travel on daily is a "smart motorway" meaning no hard shoulder so had to travel another 3-4 miles before I could pull over and restart the engine.

After restarting the engine the issue cleared and I was able to complete my journey home (another 3 miles on A roads). I drove the car over to a friends in the evening to get it scanned, (round trip of 9 miles), had no issues on the journey although I seem to think the car is a little hesitant and the idle is sometimes a bit lumpy and when driving at low speed (noticing that more and more now). We cleaned the EGR about a month ago as assumed that was probably the cause (see pics).

It's a BMR 170 TDI 2007 with near on 180k on the clock, it's serviced on time every year and hasn't failed an MOT since I last took to the *******, sorry dealer about 6 years ago.

I've driven in to work this every day since with no problem (or than the above mentioned issues).

Address 01: Engine Labels: 03G-906-018-BMN.clb
Part No SW: 03G 906 018 AS HW: 03G 906 018 AS
Component: R4 2.0l PPD1.2 G 9971
Revision: --H42--- Serial number: VWZCZ000000000
Coding: 0000072
Shop #: WSC 00450 210 69121
VCID: 76E447D6014446F40E-8022

1 Fault Found:
000665 - Boost Pressure Regulation
P0299 - 006 - ControlRange Not Reached - Intermittent
Freeze Frame:
FaultStatus: 00000001
FaultPriority: 5
FaultFrequency: 1
Resetcounter: 39
Mileage:288773 km
TimeIndication: 0
Date:2019.07.24
Time:15:38:08

Freeze Frame:
RPM: 2208/min
Torque:304.0 Nm
Speed:118.0 km/h
74.88 %
Voltage:14.13 V
Pressure:2321.7 mbar
Pressure:1895.7 mbar

Readiness: N/A

If it's the actuator as suggested on some other threads it sounds like it needs setting up so it's not a DIY job, other options I suppose is replacing the entire turbo with a recon unit as there doesn't seem to be much price difference between that and the actuator on its own.

Any suggestions on what to check first?

Many thanks,

Nick.

EGRbefore.jpg EGRafter.jpg

[Crasher]

That is underboost, normal a leak in the vacuum control system preventing the ECU controlling the boost correctly.

[nick.king]

That is underboost, normal a leak in the vacuum control system preventing the ECU controlling the boost correctly.

Morning, thank you for the reply. Is there anything I could check at home or is it a job for my local garage? Could this also cause the hesitation/juddering I'm experiencing as well when accelerating or driving at low speed?

Many thanks,

Nick.

[Crasher]

The vacuum system uses the injection tandem pump to develop the vacuum which also powers the brake servo so the first step is to remove the small pipe from the servo pipe and apply a vacuum and you should not be able to draw any air.

[nick.king]

I know this is old now but I've continued to drive the car, even did a 800 mile round trip to Newquay and that's the last time it threw this error. The juddering at idle now seems to be getting worse but there is no pattern to it happening, what I have noticed is when it's juddering on idle and then I start to drive it sounds like the exhaust is blowing (I've had it checked as I recently had the back box replaced and it's OK) and it's a little smokey around the back, as soon as it starts happening it can stop again, sometimes it's 10 mins sometimes it's a minute or 2.

I've had the turbo checked and the tests show it's the actuator at fault for the original error, I'm just wondering if the other symptoms are related or if I've potentially got other problems.

Thank you.

[Crasher]

Has the DPF been removed?

[DMitch16]

" What appears to be a leak of exhaust from the V-band clamp between the turbo and the DPF "

Get that leak fixed which will be affecting the DPF regens, but not causing low boost.

If vacuum is all ok, check for leaks in the intake piping between turbo/ intercooler/ inlet.

Moreso due to the fact you'll be breathing Nitrogen Oxide gases which affect heart arrhythmia. I know, first hand.

The V band should be a dry fit to perfectly clean surfaces, with just metal gasket and no paste or gum used. Paste / gum actually compromises the fit and is bad for the DPF. Having refitted DPFs dozens of times, they do go together perfectly if the clamp is fitted first with DPF supported and loosely bolted down on its mounts to allow a perfectly flat fit. Align properly, snug up the band then tighten the DPF mounting bolts.

[Crasher]

We have found the clamps do not like being reused.

[smitk032]

Thanks for the detailed OST Nick, really really useful. Looks like you spent a fair bit getting it sorted, too!