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2.0 TDi - Turbo Problems - Denzag
Twice in the last 2 weeks the turbo on my 2.0 TDI Golf has shut down while driving. To reset it I have to stop, switch the engine off and then back on again. I took it to the dealer who tells me I need a new Turbo that will cost around 2 grand. The car has only done 49,000 miles and is two months out of warentee. Does this sound right?

Edited by Dynamic Dave on 31/10/2007 at 13:41

Top Reply

2.0 TDi - Turbo Problems - Screwloose

OK; here it is:-


Makes: VW/Audi/Seat

Models: All TDi diesels

Years: 95-on

Engine Codes: Many

Fault-code 17965/P1557 - Upper limit of boost pressure exceeded. [Over-boost condition.]

Causes:

On ECU-integral MAP sensored types: [AFN etc. mainly pre-99.] MAP sensor's hose degraded, split, blocked by oil sludge [particularly in the bottom of any loops] or the sensor itself [in the ECU] is full of oil.

On combined MAP/IAT types with MAP fitted in the intercooler to manifold pipe: [ANU etc. '99-on] the MAP sensor itself.

On all types:

Split, leaking, porous, chafed, crushed and generally degraded vacuum hoses.

The "N75" turbo boost-control solenoid.

Incorrect duty cycle for N75 valve from ECU.

The VNT variable-vane turbo's "wastegate" mechanism sticking due to accumulated carbon.

Low system vacuum levels due to a crumbly servo vacuum pipe leaking.


Denzag

In your case; the MAP [thrust] sensor is in the intercooler ducting. There's a 50/50 chance that the vane ring on the turbo is coked. Check as advised. It is cleanable; if you're going to have a go, there is a good link with pictures somewhere. I'll try and find it if you're interested.

All Replies

2.0 TDi - Turbo Problems - Soupytwist
On what basis do they say that? What, specifically, has failed on the turbo to require replacement of the whole thing?

Do a forum search on turbo problems in diesel cars, once you've read what that throws up (it'll take you until just after Christmas) you might have some useful info. I'd try and find a diesel specialist near you to have a look at it.

Alternatively ask the dealer (and VW UK) if they think that a failed turbo after 3 years and less than 50,000 miles is acceptable, presuming it has a full and correct VW service history.
--
Soupytwist !
2.0 TDi - Turbo Problems - Screwloose
Denzag

That isn't the turbo shutting down. If cycling the key resets it; the ECU is defaulting to "limp-home" mode to protect the engine from a fault. The engine management light should have come on.

What fault-codes were found? If it was overboost [17965?] then there are many things other than the turbo that need checking first or the problem may not be cured with a new turbo.

Ask the dealer for the fault-code and enquire a price to clean the vane-ring on the turbo.
2.0 TDi - Turbo Problems - Denzag
Hi Screwloose,

Defaulting to 'limp home' mode does make sense, however no warning lights came on at all. The dealer tells me I should not be driving the car because there is a change the turbo could go completely and that would damage the entire engine, do you think this is likely or is he just trying to push me into parting with my hard earned cash?
2.0 TDi - Turbo Problems - Screwloose
Denzag

It depends on what fault-code was found - there will have been at least one.

Turbos can't just shut down; they are under direct ECU control.
2.0 TDi - Turbo Problems - Crinkly Dave
Sounds like the problem I have in the Skoda thread on this page. Same mileage etc
2.0 TDi - Turbo Problems - v6dec
Hi, I currently have same problem with 2004 Audi A3 2.0TDI, DSG. It started happening about 4-5months ago maybe once every week or two weeks and now it happens many times every day. Sometimes it can happen maybe 20 times over 30-40miles and then fine for 100mile. Especially when on the Motorway travelling at say 80MPH the car seems to hiccup and then there is no turbo, speed will fall to maybe 70MPH on the flat and maybe to 50-60MPH if climbing a hill and then maybe back to 80MPH if going down a will. If I engage Neutral and switch off the ignition and restart it's perfect, turbo works fine and then maybe same could happen within 2minutes. I've changed the EGR Valve and the EGR flap (I swapped these from another car) and the same problem. The fault reported on vag-com is "Turbo Over-boost intermitant", sometimes the Diagnostcs light comes on but most not always, when it comes on it normally goes out after a day or so. I'me not sure what else to try and it looks like replacing the Turbo, the car is only 3.5yrs old and 25k on the clock. I have no choice but maybe to change the Turbo, but I honestly thought that a Turbo stays broken if blown...This issue is more electronic hence the ignition off/on when resets until the next time and same again. The engine is the VGA 'BKD' engine code which is the same as most GT-TDI 140 Golfs. If anyone has any idea's or if you honestly believe that it's the turbo or can shed any light on the problem please let me know. I would really appreciate any information that anyone may have, thanks.
2.0 TDi - Turbo Problems - Aprilia
Could the fault code be accurate - i.e. it really is overboost due to vanes sticking and car is being thrown into limp home?
2.0 TDi - Turbo Problems - 659FBE
Check the variable vane actuator for freedom of movement. This should be done with VAGCOM but there's a simpler way which works most of the time.

With the engine stopped, find the VNT actuator capsule on the turbocharger. There is a small diameter black cotton covered rubber vacuum hose connected to it. Remove this hose (push it off with a screwdriver, don't pull). Now connect a length of small diameter rubber hose to the VNT actuator nipple.

Feel for the actuator rod under the capsule whilst sucking hard on the (new) hose. You should feel the rod move smoothly towards you as you suck. You have to suck pretty hard to get full travel - about 20mm. At full vacuum, put your tongue over the pipe and check that the actuator rod remains fully pulled in - this checks the actuator diaphragm for leaks. Now release the vacuum with your tongue and check that the rod moves smoothly back - all the way. It doesn't "click" back like the EGR valve, but there should be no stiction.

I would recommend giving the VNT mechanism a work-out in this way from time to time. It gets very sooty in the turbine housing and these things are apt to stick - giving overboost.

659.
2.0 TDi - Turbo Problems - Screwloose
v6dec

You've got the very common 17965 "overboost" code. I've answered so many of those that I've got a cut-and-paste answer somewhere..... I'll be back later.
2.0 TDi - Turbo Problems - Screwloose

OK; here it is:-


Makes: VW/Audi/Seat

Models: All TDi diesels

Years: 95-on

Engine Codes: Many

Fault-code 17965/P1557 - Upper limit of boost pressure exceeded. [Over-boost condition.]

Causes:

On ECU-integral MAP sensored types: [AFN etc. mainly pre-99.] MAP sensor's hose degraded, split, blocked by oil sludge [particularly in the bottom of any loops] or the sensor itself [in the ECU] is full of oil.

On combined MAP/IAT types with MAP fitted in the intercooler to manifold pipe: [ANU etc. '99-on] the MAP sensor itself.

On all types:

Split, leaking, porous, chafed, crushed and generally degraded vacuum hoses.

The "N75" turbo boost-control solenoid.

Incorrect duty cycle for N75 valve from ECU.

The VNT variable-vane turbo's "wastegate" mechanism sticking due to accumulated carbon.

Low system vacuum levels due to a crumbly servo vacuum pipe leaking.


Denzag

In your case; the MAP [thrust] sensor is in the intercooler ducting. There's a 50/50 chance that the vane ring on the turbo is coked. Check as advised. It is cleanable; if you're going to have a go, there is a good link with pictures somewhere. I'll try and find it if you're interested.
2.0 TDi - Turbo Problems - dieselnut
I'll save you the trouble Screwloose :-
www.technologie-entwicklung.de/Gasturbines/VNT15-T...l
2.0 TDi - Turbo Problems - rtj70
For someone to ask if a turbo on a VW could fail at such a young car age and mileage... my VW Passat petrol turbo was delivered with a faulty turbo... so VW quality control not great. This was 2000 mine so they have have improved but I doubt it. The Golf GTI 1.8T was delivered in 1999 with a faulty gearbox.
2.0 TDi - Turbo Problems - daveyjp
A friend has just had a new turbo on his Audi A3 2.0 TDi 140 at a year old and 30,000 miles. Whether it was needed one or not is another matter (like OP changing it is easier than finding the problem and sorting it out), but it's a company car and checking the oil isn't a job he ever does - 'that's what he warning light is for' and I doubt it gets the right stuff when he does top it up.
2.0 TDi - Turbo Problems - Ollie Golf
I have a GOLF mk5 GT TDI

it had a overboosting code

turbo was replaced

but now still getting overboost

wastegate has been replaced

and intercooler this was the air pressure readings current charge air pressure 2601 mbar ( max allowed 2346) and charge
> air pressure duty cycle 11%. ( normal 40-90%)

intercooler has been changed

next option is put a dump valve on it


N75 valve has been replaced and all pumping cleaned and checked

about to take turbo out and send it back to get a new one

anything else i can try before taking turbo out
2.0 TDi - Turbo Problems - Roly93
I don't think this sounds like the actual turbo itself at fault. This VaG engine is not prone to turbo problems as far as I know.
As someone else has pointed out thios is probably a non-turbo related sensor problem causing this limp home mode to happen.
2.0 TDi - Turbo Problems - Mystry1
Hey i have the same problem, what did you end up doing to fix it?
2.0 TDi - Turbo Problems - Obijez
My turbo failed, filled the engine with swarf and turbine blades - engine would not switch off and almost caught fire. 45k miles 3 years 3 months old. Result £6k bill for new engine + exhaust.

Turbos do not necessarily failsafe so don't necessarily ignore dealer advice. Sadly there was no warning of imminent failure. My advice to prolong engine/turbo life is to let the engine idle for 10s before switching off to give the turbo a chance to spool down.
2.0 TDi - Turbo Problems - mr robinson
a few weeks ago when pushin my car, usually as i hit between 80-90mph i would lose most my power, once i turned the engine off and back on it be fine again, my guess was it was going into a safe mode, then last week it started happening a lot more frequent to the point where it happened 4 times in 1 journey and was avin to hold the clutch down and restart whilst driving, and then what i think is the ECU light came on and the words emmissions garage come up, rather than pay a lot in a garage i looked into it myself and i barley know anything about cars, i put my car on a ramp, i changed the oil putting in castrol edge and changed the oil and fuel filter, i then checked the piping, from the intercooler all the way to the exhaust, i noticed on the drivers side of the intercooler, the bottom righthand pipe had a slight bit of black sludge on the join, i cleaned it as to me i thought shouldn't that be airtight? it weren't that loose and i couldn't pull it away from the intercooler, so i decided to cable-tie as best as i could to pull the pipe tighter to the intercooler, i then took it 4 a spin and a few days later i drove it 150miles with no problems, the following day the ECU light went out, i do honestly beleive i found the problem and fixed it, my car is a 2006 VW jetta 2.0tdi with 68k on the clock, i hope this might help someone and it is definetly worth checking out before costly trips to the garage
2.0 TDi - Turbo Problems - yantay

I have the same problem with my 2007 2.0 Petrol FSI golf. But VW cant find any faults, their computer comes up with nothing. I've taken it in twice. And it happens only occasionally. Any suggestions?

2.0 TDi - Turbo Problems - jabbs25

I am having a problem with my 2004 Mk 5 Golf 1.9 TDI. Yesterday whilst driving I lost all power and dark smoke appeared to be coming out of the exhaust and a hissing sound when i attempted to accelerate. Does this mean my Turbo has gone? or is there another problem? Can anyone help with my issue?

2.0 TDi - Turbo Problems - dieselnut

Sounds like a leak in the air pipe somewhere between the turbo / intercooler / inlet manifold. It could be a loose clip or a split in the rubber pipe.

Splits ony show up under pressure but usually leave a telltale spray of oil on something nearby. Take a good look.

2.0 TDi - Turbo Problems - Tom.C
Hi guys...from South Africa. My 2
2.0 TDi - Turbo Problems - markono

did you have any joy cleaning the turbo?

2.0 TDi - Turbo Problems - Railroad.

Before removing and stripping the VNT turbo to clean it I would suggest using Innotec Turbo Clean. Before anyone says otherwise I've used this stuff on three VNT turbos now and all three have worked wonders. In fact I used it on a Mondeo TDCi and had to strip the turbo in situ to add the Turbo Clean product. I was amazed at what I saw. The vane ring was stuck solid, but after I'd used the Turbo Clean it was prefectly clean and shiny and as free as I could have ever imagined. When I drove the car up the road the problem was cured, and the customer has been back in since and commented that his car has never run so well.

I'm usually the first to be sceptical of these kind of products but this stuff works, believe me. It'll be the best £40 you ever spent.....

http://www.innotecworld.com/c-1064-turbo-clean-set.aspx

2.0 TDi - Turbo Problems - Tom.C

Lost me previous post....My Touran does excactly the same as described by the original post. I'm in South Africa & live 150km from the nearest dealer. The dealership qouted met a new tubo (which you've convinced me is not neccessarily the broken) & the AIR MASS METER? Does this make sense to you also? I'm collecting the car tomorrow & I've already oredered the part & will be installing this myself. Will it then be safe to drive (140km) to the nearest turbo specialist? Tx

2.0 TDi - Turbo Problems - madf

Air mass meter and turbo? Sounds like they have no idea...

Step 1 clean air mass meter - usual caveats about not touching, use carb cleaner

Turbo vanes probably gummed up: you can strip and rebuild..

You should clean EGR valve and ALL intake tubing/pipes to and from turbo as well.. for oil/carbon etc..

Welll known turbo problem..

Edited by madf on 08/03/2012 at 15:42

2.0 TDi - Turbo Problems - Kelkinski
I have a mk4 GT TDI golf and since just before it was mapped I've had the over boost problem, VAGCOM threw up the code mentioned earlier in the thread and my boyfriend has been trying this n that to get it sorted. A couple days ago he found a boost leak on the pancake pipe where it joined the Intercooler. So replaced that. On the way home I was giving the car some stick n blew the Intercooler clean off the car! Almighty bang and lots of black smoke -and oil! So I Poodled home with him following in his V6. More embarrassing than the walk of shame when your lil golf is louder than fire force one jet funny car ?? Anyhow the following day he took the intercooler off and checked over all pipes and sensors and found a pipe (not sure where abouts but near the turbo somewhere) that was perished in one spot in the middle of the length of pipe. It was a thread covered 4mm internal diameter hose. Goes from near the top back of the engine down to... well I don't know it went down into something. He then changed the Intercooler and pow! My car is fixed the boost leaks are fixed and the over boost is no more! No more limp mode, no jitteriness...

So the vacuum hose he changed wasn't split or damaged to look at but when pressing between finger and thumb it was soft in one place about half way along it. He said that the hose was probably collapsing at that point under boost and not creating the vacuum needed... Or something like that I'm not quite sure but that sounds about right ?? Sure you guys will make some sense of that haha (sorry)

- I'm a happy woman I have my golf back ??
2.0 TDi - Turbo Problems - jferrari999
I starting having the same problem with turbo overbook the on my 2010 Jeep Patriot. I visited many forums and found there to be a common problem with this and other similar VW engines at around the 40k plus mileage!
I had been informed by two garages that it would need a new Turbo costing upwards of £1000 to a quote of almost £2000!
Fortunately,an engineering friend of mine who as a hobby, rebuilds Jensen Interceptors told me to check the oil level! I laughed as neither the warning light had come on and it had only done 4k from a full service. He said that a low oil pressure will automatically cut out the turbo in order to save damage! Well he was right, it took just half a litre and the car has been perfect since. The guile doesn't have obvious signs of burning oil but I now keep an eye on it regularly and top up accordingly. 10,000 miles on and not one incident of turbo overbook the has occurred!
 

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