2004 1.9 Pd

[stevegrass777]

2004 1.9 Pd AWX


I have done a bit of work on this engine (head off inspected cleaned put back together, Turbo off striped cleaned variable vanes cleaned put back together) anyway now it's time to start it and see if it explodes or runs,
Well the good news is it runs, The bad is not for long?
Now the key goes in the immo lights up on the dash then goes out then it starts I rev it up and it dies and sounds a bit heavy on diesel (diesel knock/growl).
Anyway no fault codes but i have found out that it runs with the MAP sensor unplugged and will rev up no problem and doesn't stall but with it connected it runs for a short time on tick over and less if i rev it a little.

Also on the readiness screen I have MIL off Components pass fuel sys Fail / incomplete egr fail /incomplete.

Any ideas welcome im a bit stuck at the mo


this car has had slight water damage if you wonder why i have striped a 04 engine just for a spring clean...

[stevegrass777]

Ideas anyone?

[boater]

Sorry to hijack your post!

When you had the turbo off to check the vanes, when the rod is disconnected from the actuator, does it move very freely?
Or does it still feel firm as it rotates the ring?

Got one driving me up the wall and cant pm you until ive done 5 posts, I am not far from you.
rgds

[snapdragon]

It should move as though disconnected - zero effort. It's not really doing much all told.

[boater]

I was hoping you wouldnt say that!

Just pressurised the turbo pipes but no leaks.

A log road test showed the rpm average 3000 rpm /spec intake press.2300[average]

actual 1500 [average] duty cycle map 35% [average]

when 3000rpm exceeded 2325 spec intake press./ actual intake press. 1100 dropping to 950
d.cycle map92%

When it reached 3300rpm it went into limp mode and the boost pressure dropped to atmospheric.
would the 1500 atm.it reached indicate the turbo is working?

The lever was very free to move, would this indicate the vanes are free?

Any suggestions please?

[stevegrass777]

Fixed it now it turned out to be the EGR valve !

Boater
The rod on it's own should be very free but the actuator is spring loaded
(i think) and stiff but you can move it a bit with a screw driver.
You should be able to get the actuator moving with a vacuum device (mity vac)
or any other vacuum pump.
These turbo's are quite prone to sticking turbo vanes when they have done a bit of work but mine was stuck because of water/condensation causing corrosion and soot hardening.
A pd turbo should reach 2000-2100 mbar before it backs off but check all the pipes (and seals) as leaks are more common.

[boater]

Thanks for the reply.
I removed the turbo today to check the vanes.
Everything clean and nice, took turbo to local turbo clinic who said it was ok.
Removed and cleaned all pressure pipes, drained some oil out of intercooler, refitted pipes and did pressure test between turbo and joint before egr /manifold... no apparent leaks.

removed egr valve assy, cleaned valve and flap.

new mas.
new maf
new boost control valve
checked all vacuum pipes
run car while operating turbo actuator rod with vacuum pump.
.
Still only achieving max pressure of 1000 >1200atm.

Any suggestions please?

How can I test for backpressure in the exhaust?


[its a 2003 passat 130 sport tiptronic] fault 17964 / p1556 charge pressure control negative deviation

[stevegrass777]

Well you have been busy, I took the small vacuum pipe off the EGR

I cant think what yours could be yet.

I dont know how to check for back pressure but you could always
leak some exhaust gases by undoing some bolts (before the cat mabe the back of the turbo) and see if it improves.

Have you done a log of the specified and actual intake pressure on a run.

What is 1000 >1200atm mine is in mbar atm? and how are you obtaining the readings.

What is the car doing to get to this stage what are the symptoms?

[boater]

Thks again for the reply
The symptoms are car is ok up to 60 or 2,500 ishrpm
any hills into limp mode it goes.

just went like that.

Did log of requested pressure....2,400 ish....actual 1000 ish

sorry was mb!

using vagcom version 805.0 from rosstech.

Will try backing off nuts behind turbo and sticking cottonwool in my ears to try it.

my business is digital dash repairs and mileage correction,
finding this problem is driving me up the wall.
I am in Cheshire not far from you.

Any advice welcome


Thanks again for your input

[boater]

Loosened 3 nuts on turbo joint, bingo!

Pity Rosstech wiki didnt offer this as a possible solution to 17964/p1556!

Just got to determine whether its back box or cat blocking it up.

Thanks for the help and advice

[boater]

Hi again
It was cat blocked.
Thks for inputs