BiTdi Electronic Turbo Actuator?

[M3 Compact]

2012 3.0 BiTdi 129K miles.

Glow plug light started flashing today and the car went into limp mode..

VCDS scan revealed various faluts relating to actuator/solenoid/short to power, but after clearing the codes a couple of times, these are consistent...




Address 01: Engine Labels: Redir Fail!
Control Module Part Number: 4G0 907 589 A HW: 4G0 907 589
Component and/or Version: 3.0BTD EDC17 H21 0004
Software Coding: 122A4012057601020800
Work Shop Code: WSC 02391 785 00200
ASAM Dataset: EV_ECM30BTD0114G0907589A 001005 (AU57)
ROD: EV_ECM30BTD0114G0907589A.rod
VCID: 326CC18A65B421D12F-8066
3 Faults Found:

5319 - Control Circuit for Controller for Turbocharger 1 (J724)
P3348 00 [036] - Electrical Malfunction
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 208979 km
Date: 2020.01.24
Time: 17:51:59

Engine speed: 1556.50 /min
Normed load value: 73.3 %
Vehicle speed: 10 km/h
Coolant temperature: 45 °C
Intake air temperature: 14 °C
Ambient air pressure: 1000 mbar
Voltage terminal 30: 13.200 V
Unlearning counter according OBD: 40
Accelerator pedal travel: 24.08 %
Charge Pressure Actuator: activation: 96.20 %
Charge Pressure Actuator: acknowledgment: 55.70 %
Turbocharger boost control: offset closed: 0.00 %
Turbocharger boost control: offset open: 0.00 %
High press turbocharger actuator: actual uncond volt value: 2648.8 mV

9126 - Actuator Module for Turbocharger 1
P00AF 00 [032] - Stuck
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 208979 km
Date: 2020.01.24
Time: 17:14:59

Engine speed: 809.00 /min
Normed load value: 20.8 %
Vehicle speed: 0 km/h
Coolant temperature: 53 °C
Intake air temperature: 29 °C
Ambient air pressure: 1000 mbar
Voltage terminal 30: 14.480 V
Unlearning counter according OBD: 40
Accelerator pedal travel: 0.00 %
Charge Pressure Actuator: activation: 5.00 %
Charge Pressure Actuator: acknowledgment: 100.63 %
Turbocharger boost control: offset closed: 0.00 %
Turbocharger boost control: offset open: 0.00 %
High press turbocharger actuator: actual uncond volt value: 4281.4 mV

9127 - Actuator Module for Turbocharger 1
P00AF 00 [167] - Stuck
MIL ON - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 208980 km
Date: 2020.01.24
Time: 18:21:11

Engine speed: 0.00 /min
Normed load value: 0.0 %
Vehicle speed: 0 km/h
Coolant temperature: 60 °C
Intake air temperature: 12 °C
Ambient air pressure: 1000 mbar
Voltage terminal 30: 11.760 V
Unlearning counter according OBD: 40
Accelerator pedal travel: 0.00 %
Charge Pressure Actuator: activation: 100.00 %
Charge Pressure Actuator: acknowledgment: -4.82 %
Turbocharger boost control: offset closed: 0.00 %
Turbocharger boost control: offset open: 0.00 %
High press turbocharger actuator: actual uncond volt value: 254.0 mV




Google indicates the possibility of a failed Hella electronic actuator?

TIA.

[dean warren]

- Stuck
MIL ON - Not Confirmed - Tested Since Memory Clear
.

I had this one last year, audi wanted to replace the biturbo unit at 5k, tps said there is a repair kit @£380 which I believe was the actuator, unfortunately was on back order and took 5 weeks to arrive, was fitted under warranty and car has been fine since.


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[M3 Compact]

Thanks Dean.

Quick Google suggests that replacement actuators may be available, subject to correctly identifying exactly which one I might require.

Few checks with VCDS this morning.


When I ran the output test for 'Exhaust Turbocharger 1' nothing visible happened and I'm assuming that this actuator should have cycled its lever?....









When I ran the output test for 'Wastegate Bypass Regulator Valve', it cycled the vacuum controlled lever in this short video, but I'm not sure how to check whether the range of travel is sufficient?....






EML is now illuminated, as well as the flashing glow plug light.

[M3 Compact]

I forgot to add:

There is also some 'noise' as the engine slows down on the overrun when revved at standstill; it sounds like it's releasing air/boost and it's coming from under the air filter/intake area.
I heard the noise before I plugged the VCDS in and I assumed that the problem was just a leaking boost hose.

[M3 Compact]

Left it to reset properly today, cleared the fault codes with VCDS and started it up 'gently' =
No dash light warnings and the 'expelling air sounds' weren't evident while the engine felt normal.

But as soon as it tried/needed to boost at all (up my steep drive), the glow plug light started flashing again and the overrun noises returned.

Spent some time today with Google...

I'm a reasonably competent 'mechanic' with my motorsport toys and I'm reasonably competent with VCDS as a fault finding/preference enabling tool....

I've no previous experience whatsoever with TDIs tho.

Should my No1 turbocharger's electronic actuator controller move at all during a VCDS 'output test'?
Should it be easy(ish) to move manually with the ignition off?
Was the pneumatic wastegate controller's movement (in the video) sufficient?

If I buy a direct replacement electronic actuator, will it need to be 'paired' with the turbo?

If I buy a complete new replacement BiTdi unit, will it be plug and play?

If I buy a complete refurb replacement BiTdi unit, will it be plug and play?

TIA.

[dean warren]

I believe the actuator will have to be calibrated, a used bitdi unit I expected would go straight on, a refurbished turbo, i would think its pot luck. All depends if they have the equipment to calibrate the actuator.


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[M3 Compact]

Came across your post on Pistonheads Dean, how did yours turn out in the end (waited 5 weeks for repair kit)?
Was yours a Hella actuator?
From what I've read, the repair kit covers the mechanical aspects only and there are no visible signs of mechanical damage with mine.

We disconnected the arm on the actuator today and the arm moved very freely, indicating that the variable vanes aren't sticking, so my pal dived in and removed the electronic actuator, which is a Hella.
I've read that the Hella actuators don't need to be calibrated???

Google reports that the worm drive gears are prone to failing and I'd hoped that there would be some visible signs of failure, alas not......

















Not sure what to do next, so I've taken a punt on ordering a new Hella actuator and crossed my fingers.

[M3 Compact]

FIXED!

No £6K at the Audi dealer or DIY £3.5K+ for a new turbo unit.


£182 all-in, for an allegedly "100% new old stock actuator".


For reference:

The actuator that came off was visibly fine and it even wound itself back to its default/fail position after being manually forced to open.
There were no broken gears inside the actuator and the electric motor was working.
Presumably the actuator had developed an 'electronic' fault on its board.
The replacement Hella actuator was plug 'n' play (no calibration required) and the car drives perfectly again with no fault codes registering.

Should my No1 turbocharger's electronic actuator controller move at all during a VCDS 'output test'?

YES!.....

Should it be easy(ish) to move manually with the ignition off?

No.

My 'wastegate'/variable vane ring lever moved extremely freely without any resistance or dragging whatsoever when the actuator was disconnected; the actuators aren't meant to be moved manually.


Happy days.

[dean warren]

So you just fitted the part and no calibration required?


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[M3 Compact]

So you just fitted the part and no calibration required?


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Yes Dean.

I researched it extensively on line and the reports stated that the Hella actuators don't need calibrating.

I was lucky and mine had a Hella, apparently there are 2 different types of actuator fitted to these cars and the non-Hella actuators allegedly need to be calibrated with the turbos removed. (No idea why.)