Another BKD Turbo Post

[jonathanfenton]

2006 2.0 BKD 140bhp 214,000 miles. Turbos been making the police siren for the past 100k. Only been using for short runs really so wondering if its a bit coked up as today when doing a 3rd gear upto 4k revs its stuttered and went into limp mode. Went about my day and came back an hour later and it drove home ok although didn't really push it. Plugged her in and got below code:

Address 01: Engine Labels: 03G-906-016-BKD.clb
Control Module Part Number: 03G 906 016 FF HW: 028 101 190 5
Component and/or Version: R4 2,0L EDC G000SG 7364
Software Coding: 0000072
Work Shop Code: WSC 06314 000 00000
VCID: 6CDDD6094FFDB2EB0F-8039
1 Fault Found:


16618 - Boost Pressure Regulation
P0234 - 000 - Limit Exceeded (Overboost Condition)
Freeze Frame:
RPM: 3738 /min
Torque: 310.0 Nm
Speed: 94.0 km/h
Load: 100.0 %
Voltage: 14.36 V
Bin. Bits: 00001000
Absolute Pres.: 2142.0 mbar
Absolute Pres.: 2580.6 mbar


Ran the actuator output test from VCDS and it came on and off boost ok, could really hear the police sirens. I recently fixed the heater plug on cylinder 3 which wasn't connected for some reason and since then its been smoking on start up and coming on boost till it warms up must be a coincidence!... Wondering if it just wants a good run to clear the turbo out or if its finally getting ready to change the turbo core out. Bit nervous to give it a right good blast with the fact i ended up in limp mode and can't be doing with it "running away" or breaking down on the side of the road....

thoughts?

[Crasher]

Needs a rebuild.

[jonathanfenton]

Thought as much, picking a rebuilt one up tomorrow. See if I can’t get it out with out breaking much tonight .

[jonathanfenton]

Refurbed turbo fitted and dropped the oil, surprisingly after 213k miles the old one was in good shape, tiny bit of “float”, so just starting to wear out, caught it early. Took 5 hours ish including drilling and tapping the cat to gearbox bracket where it sheared off in the cat lol. Not a bad job all in all, expected worse and for the record, BKD on this chassis didn’t need the drive shaft removing at all, loads of room on your back on the drive way on axel stands . No smoke and boosts nice and smoothly again.

[Crasher]

Without the driveshaft out, how on earth did you manage that?

[jonathanfenton]

No DPF as it’s pre dpf era, took cat and pipe off back to middle bracket and it just twisted and came through sideways through exhaust tunnel.

[PlatinumR]

No DPF as it’s pre dpf era, took cat and pipe off back to middle bracket and it just twisted and came through sideways through exhaust tunnel.

Exactly how I did my Touran without dpf, it was almost a pleasure!

[Crasher]

Next time I will give it a go.