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Old February 7th, 2018, 05:32   #1
Nugget3816
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Default Puzzled with my Beetle

Okay gentleman here's the question I've got a 2002 Volkswagen New Beetle 1.9 TDI and I don't know if it's a vacuum issue or what it is but I've replaced the actuator and if I disconnect the vacuum line to the actuator the car has no problem revving but when I hook the actuator up I can go to about 3800 RPMs and that's where it'll stop. Now if I leave the actuator disconnected and drive it down the road 1st gear 2nd gear no problem as soon as it hits third it falls on its face if I shut the car off break the vacuum start it back up no problem until I hit 3rd gear and then it falls on its face again can somebody give me an idea what to look for.
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Old February 7th, 2018, 05:38   #2
oilhammer
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What is your actual vs. requested boost?

Why did you replace the actuator (I assume you mean the VNT actuator)?

Did you adjust it correctly?
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Old February 7th, 2018, 06:05   #3
maxmoo
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When you disconect the vacuum line you are overboosting so when your ecu senses this it goes into "limp mode" in order to protect your engine from damage. Turning off the ignition resets limp mode.
Research "limp mode alh tdi" ..... volumes have been written, here and elswhere.
I would start by doing a scan for any codes stored, clearing them, driving the car and then rescanning.
And then report back.

Last edited by maxmoo; February 7th, 2018 at 06:08.
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Old February 7th, 2018, 06:16   #4
Nugget3816
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I've been working on this thing now for approximately two weeks. The reason I change the actuator is because the old one was all rusted and it was not moving there for it also seized up the actual wastegate. I have drove the car many times and every time the light comes on it's overboost and the mass air flow sensor I have taken the mass airflow sensor off, cleaned it with the mass air flow cleaner, put it back on and it still gives me the same code. The wastegate now moves freely and I have adjusted the actuator both ways and no matter what it's still overboosts every time. I guess my big concern is why is it that first and second gear it will run like a raped ape but as soon as it hits third it goes into limp mode/ falls on his face.
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Old February 7th, 2018, 06:18   #5
oilhammer
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Sounds to me like you need a new turbocharger.
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Old February 7th, 2018, 06:38   #6
maxmoo
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Quote:
Originally Posted by Nugget3816 View Post
I've been working on this thing now for approximately two weeks. The reason I change the actuator is because the old one was all rusted and it was not moving there for it also seized up the actual wastegate. I have drove the car many times and every time the light comes on it's overboost and the mass air flow sensor I have taken the mass airflow sensor off, cleaned it with the mass air flow cleaner, put it back on and it still gives me the same code. The wastegate now moves freely and I have adjusted the actuator both ways and no matter what it's still overboosts every time. I guess my big concern is why is it that first and second gear it will run like a raped ape but as soon as it hits third it goes into limp mode/ falls on his face.
I just answered your question above!

MAF's often don't respond to a cleaning on these things...try a new quality one or at least a known good one.....that may well be the cause of your limited rpm.
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Old February 17th, 2018, 08:56   #7
Nugget3816
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Okay change the maf sensor and I still have the exact same problem now it's showing over boost on the turbo so I really haven't changed anything after changing the MAF sensor.
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Old February 17th, 2018, 08:59   #8
Nugget3816
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Okay let me rephrase that I still have my overboosting problem but that's only if I disconnect the vacuum hose if I leave everything hooked up it does not climb over 4000 RPM and it still falls on its face after 3rd gear
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Old February 17th, 2018, 09:15   #9
flee
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Time to get back to basics. See: Diagnosing and Fixing Limp mode for A4 1.9TDI by Canadian_Grizzly
Read through this and follow the information methodically.
With luck you will find the component(s) that are causing limp mode and fix it.
The likely candidates are:
Non-Bosch MAF,
Clogged snow screen,
Plugged intake and/or EGR,
Leaking vacuum pump fitting,
Leaking vacuum hose(s),
Leaking brake booster hose,
Failed or plugged N75 valve,
Improperly adjusted actuator,
Failed or misconnected check valve(s), etc.

You need a vacuum gauge to check most of these.
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Last edited by flee; February 17th, 2018 at 09:24.
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Old February 17th, 2018, 09:19   #10
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Could be that the N75 sucked in the residue from the rusted VNT actuator. You can try cleaning it or better yet test it with a vacuum pump. Mine had a lot of contamination from the actuator; so I just replaced that along with the actuator.
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Old February 17th, 2018, 09:50   #11
Nugget3816
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Changed the N75 still same issue
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Old February 17th, 2018, 18:37   #12
maxmoo
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Quote:
Originally Posted by flee View Post
Time to get back to basics. See: Diagnosing and Fixing Limp mode for A4 1.9TDI by Canadian_Grizzly
Read through this and follow the information methodically.

With luck you will find the component(s) that are causing limp mode and fix it.
The likely candidates are:
Non-Bosch MAF,
Clogged snow screen,
Plugged intake and/or EGR,
Leaking vacuum pump fitting,
Leaking vacuum hose(s),
Leaking brake booster hose,
Failed or plugged N75 valve,
Improperly adjusted actuator,
Failed or misconnected check valve(s), etc.

You need a vacuum gauge to check most of these.
http://forums.tdiclub.com/showthread.php?t=179589
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Old February 17th, 2018, 19:47   #13
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Are you using anything to monitor Turbo Boost? .... VCDS or Scan Gauge! It would be interesting to see the maximum boost.

Also, have you confirmed that the vacuum hose from the Actuator to the N-75 doesn't have a hole in it ... losing vacuum?

At idle, there is full vacuum on the Actuator. Do you know for sure that the Arm on the Turbo is fully down on the set screw when the engine is at idle?
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Old February 19th, 2018, 12:16   #14
Nugget3816
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The arm isn't fully down on the set screw, if I get it to go fully down then it maybe moves about 1/8 of an inch if it's lucky.
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Old February 19th, 2018, 17:30   #15
maxmoo
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These vids may help you, if you haven't already seen them....

https://www.youtube.com/watch?v=A476plY-sjo
https://www.youtube.com/watch?v=K6-dXv8IrZY
https://www.youtube.com/watch?v=gYkNMOzsk14
https://www.youtube.com/watch?v=o1Hvt2b7PL0
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