Loss of power in high revs/high load

[bannervw]

I've had power problems on my B5.5 Passat (05, 130bhp, AWX) for a while. I thought it was down to the flexible exhaust coupler leaking badly. I had VW do a service on it I had a new flexible welded in right after the service. There's no more smell but still power problems (it feels like no turbo) for eg. 40mph in 3rd gear. I brought it back to VW and they say they have to replace the EGR valve @€500, as there is a EGR fault in diagnostics. All faults cleared during the service but emissions workshop message popped up and check engine light came on soon after the service.

From the report during the service there are the following faults:

P3130 EGR system Control limit reached
Fault type 1: lost23
Fault type 2:Intermittant

P1556: Charge press. ctrl. Value below lower control limit
Fault type 1: lost23
Fault type 2: Intermittant

I noticed that the shudder valve doesn't budge when I turn off the engine. It moves easily when I use my finger.

It looks like I may have a vacuum problem, anyone have any idea what to troubleshoot to try and resolve this power problem?

[zollaf]

you have a vacuum leak somewhere. find it and i am sure all the problems will disappear.

[bannervw]

I'm thinking I'll go after the small braided hoses first. Are these 3mm inside diameter? Halfords have 3.2mm hose. If anyone has a good website for the vacuum hose let me know, I can't find anything except Ebay.

[zollaf]

yes, the 3.2 will do. or you can buy silicon off the roll from a lt of places, including ebay. should be easy to find the leak though. if there is a vacuum resevoir thing on the side of the engine, remove the pipe from it and suck. where air gets in is the leak. also, across the bulkhead where a few pipes are bunched, behind engine on drivers side, theres a pipe that often gets pulled apart just there.

[bannervw]

I've pulled the hose off the top of the thing attached to the turbo. The hose leads to the vacuum reservoir. I sucked on that and had no resistance and blew air too with no resistance. It must be gone. Also I sucked/blew into the hose coming from the shudder valve, the hose is sound but I hear air coming in and out of what looks like a solenoid or something.. PN 1J0 906 283 A. As I can hear the air going in and out of it I figure it's broke and needs replacing?

[zollaf]

yeah, when the engine is running on tickover, the turbo actuator gets full vacuum so that it works, but the asv and egr get no vacuum. one test is to blank the asv and egr off, or even pipe the tuurbo solonoid straight to the t piece and go for a drive.

[bannervw]

I've realised how little sense my previous post made. I've looked up the part names..

I've pulled the hose off the top of the VNT actuator. The hose leads to the N75 solenoid. I sucked on that and had no resistance and blew air too with no resistance. It must be gone. Also I sucked/blew into the hose coming from the shudder valve, the hose is sound but I hear air coming in and out of the ASV solenoid.. As I can hear the air going in and out of it I figure it's broke and needs replacing?

[bannervw]

I removed and cleaned the EGR, no effect. Then I replaced all the vacuum lines, some were pretty bad cracked etc, no effect. I ruled out the vacuum reservoir. I bought and installed a new boost control solenoid, no effect so I used it for the EGR solenoid as I believe they are the same. Finally I seem to have resolved the EGR fault at least:-) I then find a big crack on the turbo - intercooler pipe. It looks like this was the cause of my problem all along! A mechanic did tell me this was checked but they must have missed it. I had replaced this pipe with a new one only 2 years and 50k miles ago.

I presume the anti shudder valve not working is caused by the ASV solenoid not working, but it seems that this doesn't cause any problems.