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VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old May 13th, 2014, 10:50   #1
10then34
Veteran Member
 
Join Date: Feb 2007
Location: North Dakota
TDI(s): '06 Jetta
Fuel Economy: 44-48
Default BRM EGR issue / ? Boost

I own a 2006 Jetta with the BRM engine and DSG. At 170k miles, it started to surge, had an unstable idle and eventually died and wouldn't start again. Upon readout of the codes I got:

1 Fault Found:
001027 - EGR Valve (N18)
P0403 - 000 - Malfunction

and a MAF code of some sort.

*
*
insert long painful and expensive interaction with VW of Waldorf,MD here
*
*

Got the car back to my house. Took the anti-shudder valve and EGR valve assembly off. Found:
- the gears on the anti-shudder valve worn off and stripped
- EGR valve body assembly completely coked up with the valve stuck open (taking the valve itself out of the body required a chisel and prybars )
- a small amount of oil in the rubber elbow, but not more than I would expect.

Cleaned up the EGR valve and put power to it and it would move some but never close completely. So I ordered replacements for both the anti-shudder and the EGR valve through IDIparts and installed them last night.

First trip this morning, the car smoked like a locomotive (white ) for a short while but then started to run smoothly and had a good throttle response except that it had no power. Boost would only go to about 1.45bar, no smoke. It would rev all the way to 4000rpm but just didn't accelerate well and topped out at about 55mph.

Pulled the codes, got a P0403 circuit intermittent error and when I looked at the EGR duty cycle I got numbers greater than 100% while driving. So it looked like I had still a stuck open EGR valve. So, with the valve itself eliminated, I figured it had to be the wiring. Pulled the plug off, soaked it in contact cleaner, dried it out and clicked it back in (may not have 'clicked' the first time on second thought).

Next test-drive, it smoked again like a locomotive, except that it was now black smoke !!! (that's good, right )

Now it makes power just like it used to. 100hp is nothing write home about but enough for my mother in law to run around town (the main job of this car these days). I have yet to figure out how to actually create .csv log files with my vag-com, but it looks like I get about 1.85bar of boost and the EGR now does what I expect it to do and that is to cycle in the low percentages, 15-30% or so.

So, my question to the more knowledgeable:

- what boost should I expect at full 'throttle' ?
- what are the measurements of the screw that holds the EGR cooler to the EGR body. One of those suckers disappeared into nowhereland under the hood. Looks like M8x25 or thereabouts with a Allen head.
- anything else that comes to mind

Last edited by 10then34; May 13th, 2014 at 10:53.
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Old May 14th, 2014, 11:56   #2
10then34
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Join Date: Feb 2007
Location: North Dakota
TDI(s): '06 Jetta
Fuel Economy: 44-48
Default

This is a log from a short full-throttle acceleration run uphill (I dont seem to be able to attach files). From this and other trials it looks like the boost tops out at 2.05 bar. It sometimes overshoots to 2.1 for a second or two but then levels out at 2.05.

Is that about right for a BRM at 1009.8mbar ambient pressure ?

There is no smoke and it subjectively makes as much power as it ever has.

Boost Pressure
(actual)
mbar
2009.4
1999.2
1989
1978.8
1989
2019.6
2040
2203.2
2162.4
2080.8
2019.6
1978.8
1958.4
1989
2019.6
2040
2060.4
2070.6
2070.6
2060.4
2060.4
2060.4
2050.2
2050.2
2050.2
2050.2
2050.2
2040
2040
2040
2040
2050.2
2050.2
2050.2
2050.2
1907.4
1224
1132.2
1132.2
1132.2
1122
1122
1111.8
1111.8
1111.8
1162.8
1183.2
1183.2
1193.4
1295.4
1499.4
1672.8
1917.6
1978.8
1897.2
1795.2
1683
1611.6
1560.6
1499.4
1519.8
1570.8
1611.6
1642.2
1713.6
2101.2
2009.4
2009.4
2019.6
2029.8
2040
2050.2
2050.2
2050.2
2050.2
1927.8
1224
1132.2
1132.2
1132.2
1122
1122
1122
1122
1122
1132.2
1132.2
1132.2
1132.2
1142.4
1142.4
1142.4
1152.6
1152.6
1173
1122
1081.2
1060.8
1050.6
1040.4
1040.4
1040.4
1040.4
1040.4
1050.6
1050.6
1050.6
1040.4
1040.4
1040.4
1030.2
1030.2
1030.2
1030.2
1030.2
1030.2
1030.2
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Old May 14th, 2014, 13:41   #3
Barnitz
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Location: Chillicothe/Cincinnati, Ohio
TDI(s): 2006 Jetta
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Full boost on a stock ECU should be ~15psi if I remember correctly.

To do a proper boost log, start at ~1,800 RPM in 4th gear, then WOT all the way to at least 4k RPM. Note, you can do this in 3rd gear as well if you are worried about speed. You will be going faster than any USA speed limits if done in 4th..
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Old May 15th, 2014, 22:00   #4
10then34
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Join Date: Feb 2007
Location: North Dakota
TDI(s): '06 Jetta
Fuel Economy: 44-48
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Quote:
Originally Posted by Barnitz View Post
Full boost on a stock ECU should be ~15psi if I remember correctly.
That would be 1038mbar. Given that I got 2050 with a ambient pressure of 1009, it sounds about right.

Quote:
To do a proper boost log, start at ~1,800 RPM in 4th gear, then WOT all the way to at least 4k RPM. Note, you can do this in 3rd gear as well if you are worried about speed. You will be going faster than any USA speed limits if done in 4th..
The log posted is WOT accelerating uphill and the shift-point seems to be 4100. Throughout the time I was logging, that is what it would do on WOT acceleration, overshoot a bit but then stabilize to 2050.
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