Had a busy day diagnosing and fixing faults
Posted: Mon Nov 23, 2009 4:42 pm
Bought my car a few days ago as spares or repair off ebay as it was smoking like a chimney and there were loads of warnings coming up on the mfd and loads of boost for 2 seconds then it went into limp limiting me to 2750rpm and no boost at all till it turned off and on again.
First problem i spotted was that the lower intercooler hose had a huge split in it, replaced this and it was a lot better, but after 5-10 seconds at full boost going up hills, the turbo would cut out again, and i would enter limp mode again, and i was still smoking slightly under partial throttle.
First thing i did was to blank the EGR on the inlet manifold side, made up a 1.5mm galvanised steel blanking gasket, and whilst i was there, i disconnected and blanked the dozer valve actuator (mechanically, not electrically), these 2 things seemed to sort out the smoking and made the car run a lot better, but after 10 seconds, the boost was still cutting out and going into limp mode, so i decided to swapout the boost sensor with my 806 when i discovered that the pipe linking the boost sensor to the intercooler wasnt there, and someone had screwed a screw into the intercooler takeoff as well !!
So i made up a plastic pipe that was a tight interference fit into the intercooler takoff hole, roughed it up and araldited it in, then used the rubber pipe i had taken off the dozer valve to reconnect the boost sensor, took it out for a 20 minute drive, and its like driving a new car !, runs moch smoother, resonds instantly to the throttle, and can sustain fill boost for 30 seconds plus (i didnt want to go faster than that!).
My engine light is still on, but i believe that this should go out after 20 succesfull stop starts ?
So a busy afternoon for me, and got it all finished just before it got dark !
got a 400 mile drive tomorrow to do in it, that should give it a really good test
First problem i spotted was that the lower intercooler hose had a huge split in it, replaced this and it was a lot better, but after 5-10 seconds at full boost going up hills, the turbo would cut out again, and i would enter limp mode again, and i was still smoking slightly under partial throttle.
First thing i did was to blank the EGR on the inlet manifold side, made up a 1.5mm galvanised steel blanking gasket, and whilst i was there, i disconnected and blanked the dozer valve actuator (mechanically, not electrically), these 2 things seemed to sort out the smoking and made the car run a lot better, but after 10 seconds, the boost was still cutting out and going into limp mode, so i decided to swapout the boost sensor with my 806 when i discovered that the pipe linking the boost sensor to the intercooler wasnt there, and someone had screwed a screw into the intercooler takeoff as well !!
So i made up a plastic pipe that was a tight interference fit into the intercooler takoff hole, roughed it up and araldited it in, then used the rubber pipe i had taken off the dozer valve to reconnect the boost sensor, took it out for a 20 minute drive, and its like driving a new car !, runs moch smoother, resonds instantly to the throttle, and can sustain fill boost for 30 seconds plus (i didnt want to go faster than that!).
My engine light is still on, but i believe that this should go out after 20 succesfull stop starts ?
So a busy afternoon for me, and got it all finished just before it got dark !
got a 400 mile drive tomorrow to do in it, that should give it a really good test
I do remember doing one on how to change the b*ggers but then someone else came along with a much simpler way of doing it 
