New Gal Keeps Going Into Limp Mode Problem

[jamesey]

hi im back with a new galaxy not a auto this time thank god ha ha , ive got a 2002 115 tdi 6 speed its just had the clutch and dmf done aswell but on driving it home from the garage it lost power and would not go over 3000 rpm for some reason , i turned the engine off and started again and it was fine with plenty of power but then 2 miles on it did it again ,there is no engine light on with this fault either , the garage is having a look tommorow as ive got a 3 months warenty with it. any advise would be great , dont know if its me but when i rev it from cold i can hear the turbo fluttering??

[ggobin]

sticky turbo vanes - common problem on the 115bhp - lots of info on the forum..

[jamesey]

its come back from the garage and it didnt do it with the mechanic , typical. he ugged it into the machine and it came up 3 faults , a cam sensor error a manafold sensor and flame out thats the aux heater glow plug.

the faults didnt come back so dont know what to do now , he said try it and if anything happens ring him.

[zorgman]

turbo causing overboost putting into limp mode, its in the stickys at top of page

[Dave-G]

Turbo overboost would result in a 17965 DTC.

[zorgman]

not sure on code but 592 or 572 comes to mind ill check it out end of day sometimes the code dont show up as it clears did on my car anyhow on ign cycle

[jamesey]

The garage said he can't fix it if its not doing it, but you and I know this problem is intermittent, what can I do, it keeps doing it every now and then mostly from cold,is there a way to make it do it all the time

[FLENG]

most probs the turbo need cleaning as mentioned

there is some stuff you can buy call inotec or something, its a cleaning kit and flush for the turbo to clean up the vanes, alot of the time it doesn't work as the vanes score the back plate inside the turbo so cleaning doesn't work unless you take it off and clean it properly, i had a link for the strip down and rebuild of the turbo unit with pictures and instructions i could find it for you if you want..

 

but before you change or repair the turbo, have you checked all the vacuum hoses for splits were they may have been rubbing against each other, just something you can check yourself for free but some probs the vnt mechanism

 

if you look here

it will make more sense

[Sher]

This had started to happen every morning since I had been able to do only short journeys around town for some months.

I changed the MAF for the spare I bought at 60,000 miles but the problem never went away.

A week after, because of the poor starting in the very cold weather, I changed my 4 inoperative Glow plugs (2002 115bhp 1.9TDi 117,000 miles) and drove it quite brutally, taking the engine upto 4000revs/min in 2nd and 3rd gear this problem went away after a couple of days.

I did 1600 miles to Switzerland and back last week and it did not happen once but only averaged 37mpg.

 

I suspect also the exhaust recirculation regulation valve has been faulty for upto 6 months as the fuel consumption has been very poor 33/34 mpg. I blocked it and on a busy Motorway journey I averaged 41 something it used to do. I do not recommend blocking it for long as the driveability became very poor. I was just testing it.

I intend to change the control valve.

Edited January 19, 2011 by Sher

[jamesey]

if it were the vacuumm pipes wouldnt it do it all the time , it did it on sunday just gone , and before that was xmas

now listen to this , ive picked the car up and the guy at the garage said there was no faults in the memory but when i went next door to pick the car up the mechanic said there was a turbo fault in the memory , whats going on here , im being fobbed off or what :lol: B) B) :lol: :angry2:

[paulh]

Stick a tank of decent fuel in it (Shell V power or something like that) and take it for a good long blast up a motorway.

[chrispb123456]

This had started to happen every morning since I had been able to do only short journeys around town for some months.

I changed the MAF for the spare I bought at 60,000 miles but the problem never went away.

A week after, because of the poor starting in the very cold weather, I changed my 4 inoperative Glow plugs (2002 115bhp 1.9TDi 117,000 miles) and drove it quite brutally, taking the engine upto 4000revs/min in 2nd and 3rd gear this problem went away after a couple of days.

I did 1600 miles to Switzerland and back last week and it did not happen once but only averaged 37mpg.

 

I suspect also the exhaust recirculation regulation valve has been faulty for upto 6 months as the fuel consumption has been very poor 33/34 mpg. I blocked it and on a busy Motorway journey I averaged 41 something it used to do. I do not recommend blocking it for long as the driveability became very poor. I was just testing it.

I intend to change the control valve.

 

 

if it were the vacuumm pipes wouldnt it do it all the time , it did it on sunday just gone , and before that was xmas

now listen to this , ive picked the car up and the guy at the garage said there was no faults in the memory but when i went next door to pick the car up the mechanic said there was a turbo fault in the memory , whats going on here , im being fobbed off or what :lol: B) B) :lol: :angry2:

You guys have you physically looked through the air intake of the EGR valve, the oily soot builds up in here which restricts air flow which can cause the MAP sensor to resister an overboost, blanking off the vacuum pipe will stop the EGR working which will stop further soot building up but the valve needs to be clean to start with, and it doesn't cost anything just a bit of time and scraped knuckles B)

[Sher]

looked through the air intake of the EGR valve,

 

So do I need to remove the bulkhead plate, disconnect the pipework to the left, stick a vac nozzle in?

 

Any further guidance appreciated.

 

 

One thing I noticed whilst fiddling with the vacuum pipe. The heater water pipe with a sleeve along a section of it.

On the section going away from you towards the cabin, had a groove I could feel which I presume was from rubbing against the large pipe clip underneath.

I promptly placed two pieces of gaffer tape on the underside of the pipe and around to reduce the chance of it falling off when the pipe is hot?

[chrispb123456]

looked through the air intake of the EGR valve,

 

So do I need to remove the bulkhead plate, disconnect the pipework to the left, stick a vac nozzle in?

 

Any further guidance appreciated.

 

 

One thing I noticed whilst fiddling with the vacuum pipe. The heater water pipe with a sleeve along a section of it.

On the section going away from you towards the cabin, had a groove I could feel which I presume was from rubbing against the large pipe clip underneath.

I promptly placed two pieces of gaffer tape on the underside of the pipe and around to reduce the chance of it falling off when the pipe is hot?

You need to remove EGR valve to do it properly its a dirty job if you got delicate hands make sure to use barrier creme, it can be quite stubborn removing crud from valve which you can dig out with small scraper or screwdriver a can of carb cleaner is useful to finish it off.

removing the small exhaust tube from under EGR is the worst part, definitely remove bulkhead plate its only three bolts.

[Jayton]

Hey all,

 

Have a read of this detailed guide:

http://uk-mkivs.net/forums/t/394072.aspx

 

I know it's for a MK4 Golf, but they use the same TDI PD engines as the Shalaxy's so still applies to us and well worth the read :)

Edited January 20, 2011 by Jayton