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Help: 2.0 TDI P2563 - Boost pressure control valve, implausible signal

 
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Frison90



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Post02-06-2022, 23:43    Subject: Help: 2.0 TDI P2563 - Boost pressure control valve, implausible signal Quote

Hello, dear diesel mechanic community icon_smile_thumb_up.gif.
For a long time, I've been a silent reader of this forum, and I've always been able to find something that helped me troubleshoot problems. However, this time, I haven't been so lucky. Therefore, I am trying this with this post icon_smile.gif. Please excuse me if I have overlooked a suitable post in the search or if this one is misplaced. icon_lol.gif

Okay, so now let's get to my problem, and I hope you can figure it out better than I can.
It's a VW Crafter 2.0 TDI CKTC with 127,000 km on the odometer.

The error code P2563 keeps recurring, manifesting as a flashing glow plug light, and occasionally the check engine light also comes on. Initially, the error only appeared when the vehicle was being turned off or when maneuvering into a parking space. Later, the error became more frequent, and now it consistently appears a few seconds after the engine starts.

I have already checked all the cables and vacuum hoses for damage.
Turbocharger and boost pressure sensor replaced (suspected carbon buildup in the variable geometry turbocharger).
Boost pressure sensor tested for vacuum leaks > leak-tight and functioning correctly.
Vacuum system tested at 0.5 bar > leak-tight and holds pressure.
Disconnected the connector from the boost pressure sensor > The error appears immediately, even before starting the engine.
AGR valve removed and inspected.

0.5 bar of boost pressure is reaching the boost pressure sensor directly when starting the engine.
However, after a few seconds, the error appears, the vacuum in the intake manifold immediately disappears, and the pressure returns to 1 bar.

Do you have any suggestions on where I could continue troubleshooting this "set" error?
You would be a great help to me! I'm slowly running out of clues about where I could continue searching. icon_question.gif

Thank you in advance, and best regards from Ingolstadt!
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Post03-06-2022, 9:19    Subject: Help: 2.0 TDI P2563 - Boost pressure control valve, implausible signal Quote

Hi,

Wow, turbo replacement... Quite a few euros have already been spent on the repair attempts.
Have you checked the live data values in VCDS? If the error occurs while the vehicle is stationary, you should be able to directly see which actual value is not following the expected value. What do the target and actual boost pressures look like after the engine starts?

Regards,
Guste.
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Frison90



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Post03-06-2022, 11:28    Subject: Help: 2.0 TDI P2563 - Boost pressure control valve, implausible signal Quote

The actual boost pressure is not reaching the target value, and this was already the case before the turbo was replaced. The diagram clearly shows how the target boost pressure increased rapidly, while the actual boost pressure followed more slowly, but eventually reached the target value.

I just read some more boost pressure and boost control solenoid values while the engine was idling.
I noticed that the boost pressure sensor only provides feedback at around 60%, even though 100% is requested. Do you have any idea what might be causing this?
Do you need to "calibrate" anything when replacing the turbo?



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Post03-06-2022, 13:01    Subject: Help: 2.0 TDI P2563 - Boost pressure control valve, implausible signal Quote

Here, there's a fundamental lack of understanding of the boost pressure control system. First, the driver of the car needs to be calibrated.

Autoscan?

Please review the following:
Okay, I'm ready. Please provide the German text you want me to translate.
Dipl.-Ing. (FH) Rainer Kaufmann - dieselschrauber VCDS Shop
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