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galaxy 2007 2.0 tdci boost issues


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#1 jas95aero

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Posted 10 October 2016 - 05:16 PM

Hi,  got a Galaxy 56plate  (2007) 2.0 tdci 140 bhp 151kmiles

Had a reconditioned turbo last year as my old one was like a police siren!.

Anyway i tow a caravan never had error codes before but since the new turbo i keep getting engine light after about an hour or so of towing driving.

Also getting a whistle noise on high boost but only when towing.

Scanning using forscan i get p003a and also (cant remember the exact code) turbo position circuit voltage too low/high.

I checked the EGR cleaned that and its all working can hear it moving when you turn the car off and no error codes.

 

The problem only occurs when towing..... putting more pressure on the the car.

Has anyone got a vacuum diagram so i can check the pipes are in correct order.

 

Also what voltage should the actuator position sensor show at idle full bost etc so i can check adjust on it.

I got a minivac tool so if someone has the correct actuator pressure i can test that. (its a vacuum/mechanical actuator not electronic)

 

Not sure what the whistling noise is? I've replaced the pipe coming from turbo to inter cooler and got new gaskets for the EGR.

I tried soapy water on the pipe from inter cooler to inlet cant see any bubble but might have to take the plunge and replace to eliminate that.

 

I've read about the EGR whistling being slightly stuck open but mine seems fine.

 

I can feel the boost almost pulsating about 1800-2000rpm then the error shows up.

 

The car goes into limp mode and a quick on/off resets it but does come back when towing. I'm assuming the ecu is going into limp as it does not like either the actuator position or boost pressure.

I've changed most of the sensors map,maf,crank,cam, both vacuum solenoids and actuator position sensor.

Had 2 services still no fix so far. All filters changed.

MPG has been quite good avg 50 normal, towing 30-38

 

Any ideas thanks in advance.

 

 

 



#2 RB2004

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Posted 10 October 2016 - 05:33 PM

When turbo was reconditioned was the vnt calibrated afterwards?




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#3 jas95aero

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Posted 10 October 2016 - 05:54 PM

it was a full reconditioned unit not the core


its showing over boost now i just scanned it, will copy the details into here



#4 jas95aero

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Posted 10 October 2016 - 06:00 PM

===PCM DTC P2263:72-64===

Code: P2263 - Turbo / Super Charge Boost System Performance

Additional Fault Symptom:

- Actuator Stuck Open

 

Status:

- DTC Maturing - Intermittent at Time of Request

- Malfunction Indicator Lamp is Off for this DTC

- Test not complete

Module: Powertrain Control Module

Diagnostic Trouble Code details

Possible causes :

An electrical fault in the Turbocharger control circuit.

MAP sensor electrical failure.

Inspect connectors for signs of damage, water ingress, corrosion, etc.

If the code is set at idle renew the turbocharger. If the code is not set at idle investigate faults with the MAP.

===END PCM DTC P2263:72-64===

===OBDII DTC P2263-P===

Code: P2263 - Turbocharger/Supercharger Boost System Performance

 

Status:

- Pending - malfunction is expected to be confirmed

Module: On Board Diagnostic II

===END OBDII DTC P2263-P===



#5 jas95aero

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Posted 10 October 2016 - 06:06 PM

===PCM DTC P0234:00-E8===

Code: P0234 - Turbo/Super Charger Overboost Condition

Status:

- Previously Set DTC - Not Present at Time of Request

- Malfunction Indicator Lamp is On for this DTC

- Test not complete

 

Module: Powertrain Control Module



#6 jas95aero

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Posted 10 October 2016 - 06:07 PM

also got live data of a short run but dont know how to upload that



#7 jas95aero

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Posted 10 October 2016 - 06:12 PM

I'm sure the vnt position was calibrated but it still threw up codes when towing. from what i can remember the error codes stated either circuit voltage too low or too high



#8 RB2004

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Posted 10 October 2016 - 06:19 PM

Was it sent away for recon or purchased as recon from a reputable source?

If it was sent away for recon a number of possibilities.

Firstly, actuator sensor was not replaced. These screw into top of the actuator and report position to ecu.

The vnt mechanism is sticking, not a normal item to be replaced during recon unless it's damaged.

Or vnt hasn't been calibrated... Only a few reconditioners have a machine for vnt calibration.

You will know if it was done because the recon ubit would of come with the certificate of calibration which you as the owner need to keep for warranty purposes.


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#9 jas95aero

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Posted 10 October 2016 - 06:30 PM

it was a full swap unit, old for new. i've replaced the position sensor. To be honest cannot find the receipt but it was about 8 months after unit was replaced that i towed and error come up.

 

I'm sure you can set the vnt position via live data, voltage of the sensor? or via vacuum pressure?

vnt arm moves freely.

 

Everything seems to be working , i think the position is out causing the errors. If someone has the voltage (or vacuum ) data of the position sensor i can adjust it to that.



#10 RB2004

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Posted 10 October 2016 - 06:38 PM

You can't set the vnt with live data.

It's done with a flow bench by adjusting the vnt stop screw and vacuum actuator.

Towing will put more of a load on the engine and it will demand more boost, especially when accelerating.

Only things which can cause overboost error codes are,

VNT fault, Actuator fault, or Map / Position sensors reading incorrectly.

Because the ecu uses the sensors to command boost, and the actuator and vnt are responsible for boost.

Not inclined to believe it's a faulty vacuum solenoid which is mounted to thermostat housing on side of head as it will do it all the time.


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