CAXA: Boost pressure error, turbocharger replacement, new turbocharger

Hi.


A CAXA (with DSG in a Golf Plus) has thrown this error three times today:

Code:

Adresse 01: Motor       Labeldatei: RKS\03C-906-016-CAX.clb    Steuergerät-Teilenummer: 03C 906 016 AJ    HW: 03C 907 309 A   Bauteil und/oder Version: MED17.5.5       G   6711                  Codierung: 0000077             Betriebsnummer: WSC 01357 011 00200                       VCID: 67D62BDE5616A420806 1 Fehler gefunden: 000665 - Ladedruckregelung                P0299 - 000 - Regelgrenze unterschritten - Warnleuchte EIN              Umgebungsbedingungen:                     Fehlerstatus: 11100000                     Fehlerpriorität: 0                     Fehlerhäufigkeit: 3                     Kilometerstand: 34666 km                     Zeitangabe: 0                     Datum: 2096.14.01                     Zeit: 09:37:39              Umgebungsbedingungen:                     Drehzahl: 2835 /min                     Last: 51.0 %                     Geschwindigkeit: 108.0 km/h                     Temperatur: 92.0°C                     Temperatur: 33.0°C                     Druck: 970.0 mbar                     Spannung: 13.970 V Readiness: 0000 0000

The first two times, they were sporadic occurrences, happening within a 150 km radius of my location.
I happened to come across them.
Then, on the way home, the drivers called and said they were at the parking lot, and the MIL (Military Police) were there.

Code deleted, drove to the next parking lot - nothing unusual.
Even for the remaining 120 kilometers of the journey home, the MIL (presumably a vehicle or device) did not reappear.

Does anyone have any insights into why this error occurs even when the boost pressure is properly regulated?

Quote:

Does anyone have any knowledge about why this error occurs even when the boost pressure is properly regulated?

Assuming the turbocharger is controlled by vacuum pressure (?), there might be a leak somewhere in the control system. Perhaps it's similar to a BMR issue, if the vacuum pipe switchover valve has a leak.

Last night, at the rest stop on the Autobahn, he refused to perform the actuator diagnosis.
Terms and conditions for... Not fulfilled.

It's strange that the diagnostic run I performed after the MIL (Malfunction Indicator Lamp) illuminated, and which I've attached here, appears completely normal, and the control valve is working properly, so the control system seems to be functioning well.

Somehow, the only remaining explanation could be that the open wastegate valve occasionally gets stuck.

Unfortunately, the N75 (if that's its name) and the WG are located underneath the turbocharger on the CAXA. It's hard to get a good look at it, just trying to see it is difficult.

The intercooler piping is made entirely of hard plastic, with no rubber hoses that a badger could puncture, which could then lead to a leak only after a certain amount of time under full boost pressure. It's not far from the front of the engine to the rear, where the water-cooled oil cooler is located.

I had an IDEA:
The boost valve!
Do the 2.0 TSI engines tend to have a lot of problems?
"Part number 06H 145 710 D is also used in this application."

At least, a valve that is stuck in the "open" position could explain "boost pressure... insufficient".


m;

Oh shit.

TPI 2020616/3
(if I had them)

Here's the translation:

"It should describe a stuck or malfunctioning wastegate, which is causing the errors."

He just performed quite well during all the active measurements yesterday, didn't he?

m;

EDIT:
Currently, the reference number for this is TPI 2020616/13.

Okay.

Now it's due.

The wastegate is no longer moving.
The external lever only moves about 1 mm to the left when pressure is applied to the can.

It's impossible to assess the "smoothness" of the TPI's return movement because it's just a twitch.

The errors are now related to low and excessive boost pressure.

Code:

Sonntag,28,Juli,2013,13:36:26:31600 VCDS Version: RKS 11.11.5 Datenstand: 20130111 -------------------------------------------------------------------------------- --------------------------------------------------------------------------------                 Adresse 01: Motor       Labeldatei: RKS\03C-906-016-CAX.clb    Steuergerät-Teilenummer: 03C 906 016 AJ    HW: 03C 907 309 A   Bauteil und/oder Version: MED17.5.5       G   6711                  Codierung: 0000077             Betriebsnummer: WSC 01357 011 00200                       VCID: 67D62BDE5616A420806 2 Fehler gefunden: 000665 - Ladedruckregelung                P0299 - 000 - Regelgrenze unterschritten - Sporadisch              Umgebungsbedingungen:                     Fehlerstatus: 00100000                     Fehlerpriorität: 0                     Fehlerhäufigkeit: 2                     Kilometerstand: 35634 km                     Zeitangabe: 0                     Datum: 2096.14.27                     Zeit: 12:30:06              Umgebungsbedingungen:                     Drehzahl: 3521 /min                     Last: 56.8 %                     Geschwindigkeit: 83.0 km/h                     Temperatur: 93.0°C                     Temperatur: 45.0°C                     Druck: 970.0 mbar                     Spannung: 13.716 V 000564 - Ladedruckregelung                P0234 - 000 - Regelgrenze überschritten              Umgebungsbedingungen:                     Fehlerstatus: 01100000                     Fehlerpriorität: 0                     Fehlerhäufigkeit: 1                     Kilometerstand: 35844 km                     Zeitangabe: 0                     Datum: 2096.14.30                     Zeit: 12:03:42              Umgebungsbedingungen:                     Drehzahl: 3616 /min                     Last: 100.0 %                     Geschwindigkeit: 112.0 km/h                     Temperatur: 93.0°C                     Temperatur: 36.0°C                     Druck: 960.0 mbar                     Spannung: 13.843 V Readiness: 0000 0000

That should give it a new turbo.

Or how far does the wastegate lever typically move?

Quote:

Or how far does the wastegate lever typically move?

More than 1mm...

Good luck, Rainer.

And a pressure test on the pressure hose BEFORE the N75 valve is also considered a valid procedure?
(You can easily get in touch with him, but it's impossible to reach the rest, because they're completely isolated.)

Because when the engine is not running or the ignition is turned off, does the N75 valve direct *all* the pressure to the wastegate actuator?

At least, the initial opening seems appropriate for a pressure of 300 mbar.

Good question, sorry, I've never taken it apart before. If the lever is difficult or impossible to move, there's likely no easy way around it...

Best regards, Rainer.

There is a new exhaust housing available as a repair kit, and the pressure sensor will also need to be adjusted.

Quote:

This includes a new exhaust housing as a repair kit,

WHAT?
Does a regular workshop disassemble turbos?

I read something about "replacing the pressure sensor" or "replacing the turbo" in the TPI.

On the other hand, the 440 EUR for a replacement part confused me, which seems to support your version.

All things considered, I hope things go well from here on out.
Possibly, I'll have someone at the workshop show me .

Thank you.
m;

Well, what does "disassemble" mean? The entire turbocharger has to come out anyway (due to the pressure rod adjustment).
The clamp that connects the manifold to the turbine won't come loose anymore. It's designed in such a way that it's meant to be replaceable.

How long do you think the new part will last, assuming it's not changed in terms of design or quality?

Oh, you're right.

The turbocharger and balancing remain unchanged.
And the stuck wastegate actuator is located in the manifold.

Okay, then I'll scratch each part with a tool so I can recognize them later.

And after 36,000 km, I'll install the exhaust manifold myself.
I can also adjust the 300 mbar setting for the wastegate opening myself .

Is the difference between /10 and /13 in TPI then due to the replacement part?
Because in the /10 that I read, it mentioned "TURBO SWAP," not "reinstalling the lock." I need to have someone show me the /13 sometime on Thursday .


m;

The replacement part has a delivery time of 10 days.

edit: Part number of the replacement part: 03C 198 722.

Super

Okay,

My workshop received some "assistance" from VW – they provided a completely new turbocharger due to the poor availability of the spare parts.

03C 145 702 C out.
03C 145 702 LX clean

Here's a summary again:
Golf Plus, 1.4 TSI 122 hp (CAXA), September 2010.
36,000 km driven.
VW covers 100% of the parts costs and 70% of the labor costs for the exchange program.
The remaining 84 EUR of the wage will be covered by the extended warranty that was purchased at the time of acquisition.


Here you can see how a new wastegate should function.

The "vonOben" videos require removing the heat shields.
Loosen 5x TX30 screws (the bottom one is barely visible).

In the "Side" view, an LED flashlight is positioned on the manifold, and you can see the "wide" movement of the wastegate – unfortunately, I don't have a video of the faulty wastegate in this version.

At 0.6 bar, my 50 ml syringe was fully depressed, meaning it was pushed all the way in.
The wastegate probably could have allowed for even more boost.

Perfect, you can see very clearly how the Wasegate moves. Well done on the video.

Nice, let's see how long it runs this well.