Loss Of Power,limp Home Mode,turbo Shutting Down

[mark.aa]

had the fault with the turbo allways shutting off under load in third gear always above 3000rpm only,

then would be ok if i restarted engine and kept engine speed bellow 3000rpm.

when i took the engine ecu apart there was air pressure inside the ecu case.it released as i lossened the case screws.

put it back in the car and it worked ok.

took it back out again and it had pressure inside it again!

think the rubber hose to the map sensor in ecu was leaking boost presssure inside case causing the map sensor to miss read.

as i think the map needs normal atmoperic pressure to reference the boost pressure to.

i opened the ecu (4 torx 15 screws) pulled out the board .

inside there is a small rubber hose that goes from the ecu case to the black plastic map sensor

i then cut the ends of the rubber hose back incase they had streched

and put a small smear of epoxy glue around the map sensor seams to seal it incase that had a air leak.

 

the bosch numbers on the map sensor were 0273 003 270 250kpa

 

to remove the ecu from the car the intruments have to be removed,2 screws on the trim 2 on the clocks then 2 multi plugs

 

ecu is under the steering support.

disconnect vac pipe on top l/h side of ecu first.

remove the security torx screw from the bracket that stops the ecu from being unpluged(t20 hollow tip)hidden between the vic pipe nipple on ecu case and the multiplug.

now push the ecu plug clip forwards and plug will slide away from ecu.

then you can access the other 2 torx 20 security screws that were under the plug

[mark.aa]

ok just tested in out ,

worked perfectly.revs through to 4600rpm and no limp home mode.

the only thing i did extra was to drill a very small hole in the ecu alloy case (1mm) to let out any pressure that may leak out of boost hose in the future,

as i am running with a red i tunning plug and play pump tuning kit,110bhp tdi to 135bhp kit that may be causing the extra boost to leak out of the hose due to highter than factory boost.

 

noticed too that i used to have a cold start fault that was almost as if the glow plugs werent working,used to crank for ages (10 sec +)then start with a big cloud of grey smoke,

this has gone too .

hope this helps somebody else with a mk1 galaxy 110 tdi going into limp home mode.

[Mirez]

Interesting post, congratulations on the fix ;)

[ricki]

had the fault with the turbo allways shutting off under load in third gear always above 3000rpm only,

then would be ok if i restarted engine and kept engine speed bellow 3000rpm.

when i took the engine ecu apart there was air pressure inside the ecu case.it released as i lossened the case screws.

put it back in the car and it worked ok.

took it back out again and it had pressure inside it again!

think the rubber hose to the map sensor in ecu was leaking boost presssure inside case causing the map sensor to miss read.

as i think the map needs normal atmoperic pressure to reference the boost pressure to.

i opened the ecu (4 torx 15 screws) pulled out the board .

inside there is a small rubber hose that goes from the ecu case to the black plastic map sensor

i then cut the ends of the rubber hose back incase they had streched

and put a small smear of epoxy glue around the map sensor seams to seal it incase that had a air leak.

 

the bosch numbers on the map sensor were 0273 003 270 250kpa

 

to remove the ecu from the car the intruments have to be removed,2 screws on the trim 2 on the clocks then 2 multi plugs

 

ecu is under the steering support.

disconnect vac pipe on top l/h side of ecu first.

remove the security torx screw from the bracket that stops the ecu from being unpluged(t20 hollow tip)hidden between the vic pipe nipple on ecu case and the multiplug.

now push the ecu plug clip forwards and plug will slide away from ecu.

then you can access the other 2 torx 20 security screws that were under the plug

 

Hi mark,

 

Thats sounds exactly the same as mine BUT........... I am not at all technically minded like you seem to be. Do i need to take my car to a specialist to have this fixed, or could i expect a normal mechanic to sort it.

 

Thanks Ricki

[mark.aa]

the instruments come out easy,just 4 screws,2 in the trim 2 onthe clocks,2 plugs in back of clocks,lower the steering colum and pull out as far as it will .

you could just drill a small hole in ecu case ~(1mm)

[zorgman]

have mentioned this fault and fix a few times but dont reuse the old pipe as it goes all gooey and claggy cost approx 30p to rix use a small length of silocone tubing or new rubber tube you only need 4".

can throw up code 0575 overboost

[skemp]

Hi,

 

I have had a diagnostics telling me I have a MAP sensor fault, and someone telling me the MAP sensor is on the inlet manifold.

 

The Haynes manual doesn't mention it?

 

The ECU has been sent off and returned with no fault showing.

 

My Galaxy is a 1.9TD Zetec 1999 110BHP, am I correct in thinking this is engine code AFN?

 

Thanks

Skemp.

[zorgman]

yes afn engine using vnt turbo, map sensor is inside the ecu which is located behind the clocks. when i done mine i done a mod using a 4.5v zenner diode so that i cant get spikes. for real good info relating only to vw tdi inc pd engines look at tdi club forums theres masses of info on there as tdi's are a big big thing in states theyhave them over 200bhp now and thats where ive learnt about all the mods that can be done safely

[chrispb123456]

yes afn engine using vnt turbo, map sensor is inside the ecu which is located behind the clocks. when i done mine i done a mod using a 4.5v zenner diode so that i cant get spikes. for real good info relating only to vw tdi inc pd engines look at tdi club forums theres masses of info on there as tdi's are a big big thing in states theyhave them over 200bhp now and thats where ive learnt about all the mods that can be done safely

Hi Zorgman just been looking at that site as you say there's tons of info on there and easy to understand :)

[GFUNK1851]

<!--quoteo(post=153880:date=Apr 28 2010, 23:11:28:name=zorgman)--><div class='quotetop'>QUOTE (zorgman @ Apr 28 2010, 23:11:28) <a href="index.php?act=findpost&pid=153880"><{POST_SNAPBACK}></a></div><div class='quotemain'><!--quotec-->yes afn engine using vnt turbo, map sensor is inside the ecu which is located behind the clocks. when i done mine i done a mod using a 4.5v zenner diode so that i cant get spikes. for real good info relating only to vw tdi inc pd engines look at tdi club forums theres masses of info on there as tdi's are a big big thing in states theyhave them over 200bhp now and thats where ive learnt about all the mods that can be done safely<!--QuoteEnd--></div><!--QuoteEEnd-->

Hi Zorgman just been looking at that site as you say there's tons of info on there and easy to understand <img src="http://www.fordgalaxy.org.uk/ford/public/style_emoticons/<#EMO_DIR#>/smile.gif" style="vertical-align:middle" emoid=":unsure:" border="0" alt="smile.gif" />

Sorry new to the site I have fault 575 and have similar symptoms only on motorways. Can anyone advise what inner and outer diameter the silicon hose has to be so that I can buy the neccessary bit before I take my car apart. GREAT POSTs !!!! by the way guys, fingers crossed might save me a few hundred pounds in Garage fault finding.