P0299 fault after turbo change on Ford 1.8TDCi

b318isp

The turbo went on out '07 Galaxy last week, so a recon was fitted. Ever since, I'm getting the EML light and P0299 underboost code.

The car feels lazy, with no real boost low down, but it does eventually kick in. Here is the graph of the boost pressure:


Untitled by b318isp, on Flickr


Untitled by b318isp, on Flickr

The one with the single peak is in third covering ~1600-3000rpm, and the pic with two peaks is in second - each peak covers roughly 1600-4500rpm. You can see that the pressure rises steadily, however there is no kick at around 2000rpm. Normally the car picks up noticeably around 1800rpm.

When the original turbo went, only a small amount of oil was lost into the exhaust.

So, since the change, the following was checked:

- Intercooler removed, about half a thimble of oil came out
- Intercooler main pipes check for cracks, all OK
- Intake pressure sensor degreased, no faults
- MAF checked, no faults
- Hoses around the inlet manifold checked, no obvious problems
- NO EGR fault

Any ideas - I've only the EGR to strip left in my head...

sandydan

i cant help you with diagnostics but having had repeat of turbo trouble in avensis i hope it was well serviced before and after fitting turbo have a look at this posted by gctest50 in turbo trouble . good luck

http://www.assuredperformance.ie/assets/images/Presentation-1.6-hdi-carbo-issues.pdf

b318isp

Thanks. I'll have a read of that.

EGR was checked at the weekend. Slight sooting, but no major build up.

b318isp

Garage are going to pull the exhaust system (even though very little oil got in to it).

After that, will have to look at the turbo ECU...

sandydan

b318isp wrote: »

Garage are going to pull the exhaust system (even though very little oil got in to it).

After that, will have to look at the turbo ECU...

id worry about the intake side more and the condition of oil flow & pressure . i think its requirement flow is 1/3 litre per 60 seconds on outflow side of turbo, however if it was well serviced when fitting don't worry about it .
a friend had turbo trouble in passat, loads of smoke and wouldn't pull a cat out of fire, he said. he changed turbo 3 times until getting fed up and changed mechanic. it was some sensor caused it, it was cleaned and problem disappeared, he cleans it regularly since and feels the other turbos were fine. have galaxy and VW some connection.
as matter of interest, what happened old turbo,did you get it checked after, was it power loss , or black smoke or did oil seals in turbo go.

sandydan

mods I hope im not breaking any rules by posting this, if so please remove asap-
try this link there is a whole lot of info there i hope it helps

P0299 Turbo / Supercharger Underboost - OBD-Codes.com
www.obd-codes.com/p0299

Row

A Turbo underboost fault code could be anything from...

1)Vacuum (lack of) problem...check all vac hoses for leaks.
2)Boost hose split (look for oil mist around boost hoses/intercooler.
3)Turbo pressure (map) sensor....swap it out for another to test.
4)Turbo itself.

i would go tru the above steps from 1 to 4 before any major ripping..:)

b318isp

sandydan wrote: »

id worry about the intake side more . it was some sensor caused it, it was cleaned and problem disappeared, he cleans it regularly since and feels the other turbos were fine. have galaxy and VW some connection.
as matter of interest, what happened old turbo,did you get it checked after, was it power loss , or black smoke or did oil seals in turbo go.

Yes, we have focused on the intake side. The pressure sensor has been checked as OK on diagnostics and with graphed trends while running.

Ford/VW tie in was the previous generation.

Bearings went in old turbo due to oil loss (oil filter seal).

b318isp

sandydan wrote: »

mods I hope im not breaking any rules by posting this, if so please remove asap-
try this link there is a whole lot of info there i hope it helps

P0299 Turbo / Supercharger Underboost - OBD-Codes.com
www.obd-codes.com/p0299

Cheers, I had seen that - but now looking again, there are somethings extra to look into.

b318isp

Row wrote: »

A Turbo underboost fault code could be anything from...

1)Vacuum (lack of) problem...check all vac hoses for leaks.
2)Boost hose split (look for oil mist around boost hoses/intercooler.
3)Turbo pressure (map) sensor....swap it out for another to test.
4)Turbo itself.

i would go tru the above steps from 1 to 4 before any major ripping..:)

Yes, the first 2 done, 3 checked on trends as OK and no noise. 4 maybe the turbo's ECU. Thanks.

sandydan

b318isp wrote: »

Yes, we have focused on the intake side. The pressure sensor has been checked as OK on diagnostic

Bearings went in old turbo due to oil loss (oil filter seal).

mechanic showed me a turbo with what only looked like turbo oil seal gone, it was, but he claimed washed diesel and residue from it in exaust built up behind heat shield some how and damaged shaft and seals as result,sounds confusing when i cant relate full story properly but another contributor may have similar story and able explain better.
his advice was dsl tank should be cleaned with turbo change, injectors removed and new seal washers fitted , thought it was OTT, but when you look at recommendations in link of " assured performance" its childsplay...

however yours is boost cut-in timing it should be something simpler hopefully like setting of linkages in new turbo,wonder why that wasn't that an issue in old turbo, would almost consider asking refurb shop( take car, not turbo alone) to test and check as those linkages determine the angle of intake blades in some brand of turbos to vary the air pressure boost but not actual timing AFAIK. wish you luck ps have a look at this link https://www.youtube.com/watch?v=Ppif4qC560U

b318isp

sandydan wrote: »

however yours is boost cut-in timing it should be something simpler hopefully like setting of linkages in new turbo,wonder why that wasn't that an issue in old turbo, would almost consider asking refurb shop( take car, not turbo alone) to test and check as those linkages determine the angle of intake blades in some brand of turbos to vary the air pressure boost but not actual timing AFAIK. wish you luck ps have a look at this link https://www.youtube.com/watch?v=Ppif4qC560U

Thanks for this. Actuator has been validated - as linkage cannot be adjusted (it a VVT).

Current line of enquiry is now the MAP sensor - as the exhaust side has been checked OK.

sandydan

b318isp wrote: »

Thanks for this. Actuator has been validated - as linkage cannot be adjusted (it a VVT).

Current line of enquiry is now the MAP sensor - as the exhaust side has been checked OK.

ok point taken.i was just referring to illustration of how an obstruction or wrong adjustment can prevent adjustment for cut in at correct time, and the role of linkages and actuator involved . BTW did garage recondition the turbo

b318isp

sandydan wrote: »

ok point taken.i was just referring to illustration of how an obstruction or wrong adjustment can prevent adjustment for cut in at correct time, and the role of linkages and actuator involved . BTW did garage recondition the turbo

NO worries. Turbo was a recon - off the shelf.

b318isp

UPdate: no joy with the MAP sensor. Going to replace dead glow plugs tonight. After that, I've no further ideas.

sandydan

b318isp wrote: »

UPdate: no joy with the MAP sensor. Going to replace dead glow plugs tonight. After that, I've no further ideas.

how about checking the turbo if that problem did not exist with old one it may be simple piece of obstruction like grit in mechanism or adjustment