CJAA into Tiguan low boost issue

vwztips

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2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
Having a low boost issue after installing a CJAA into a 2012 Tig. Need advice from some gurus on this motor.

A quick background on my issue. I picked up a 2012 Tiguan S with the TSI and 6 speed manual back in April. Long term goal was to install a CJAA into it. I found a wrecked 2013 Golf TDI with 6 speed manual and only 51k miles. The drivetrain was in tact. The rest of the car, not so much LOL. Pulled the TSI and gearbox form the TIG, emptied and dried the fuel tank. Spent 2-3 weeks combing over both the Tig and Golf wiring schematics and formulated a game plan on how to proceed and account for every wire in the T94 plug of the ECU.

Next I took about 2 weeks to get the T94, fuse box, etc. harness transferred over to the Tig.

Next the engine was installed as removed from the Golf. It turned over about 4 times and cranked right up.

Once I confirmed the engine ran, I pulled it out, installed a new timing belt, water pump, etc. along with a CP3 fuel pump and kit. While out I also removed the EGR and DPF items with plans to tune them out.

I reinstalled the drivetrain and again it fired right up. I drove it down the road and it felt as though it was in limp mode as it would not pull a hill very well and not much giddy up. I assumed that was because I had the EGR, DPF etc. unplugged. I had a tuner write me a tune with those items out of it. Still had a limp mode issue after the tune. Did find a bad N75 valve and replaced it. Have 25 hg of vacuum, hoses are good, etc. Waste gate actuator moves freely. Still have limp mode but no codes. Tuner has tried a couple of things with the code but nothing has resolved the issue yet.

I had the opportunity to check a friends Jetta TDI manual this weekend (he turns it in next week) and do some comparisons in VCDS. Most everything is the same within reason. One thing that we have noticed is the smoke limitation is different. At idle and wide open, with the Jetta I see this in VCDS

RPM = 828
Torque Request = 0
Torque limitation = 186
Smoke limitation = 78
RPM = 2438
Torque Request = 423
Torque limitation = 369
Smoke limitation = 429

With the CJAA in the Tiguan I see this

RPM = 828
Torque Request = 0
Torque limitation = 186
Smoke limitation = 186
RPM = 2162
Torque Request = 459
Torque limitation = 447
Smoke limitation = 273

Notice the difference in the smoke limitation between the 2 at idle and wide open (wide open = foot to the floor).
I thought maybe I had a MAF issue but I swapped the MAF from the Jetta into the Tig and got the same results. Note the idle differences of the MAF between the Jetta and Tig were because of the EGR deletion per tuner.

What is driving me nuts is that there are no codes showing up on the Tig, but something is telling it to not boost. One thing I found late yesterday was that I had the Exhaust pressure sensor 1 (G450) plugged in but the rest of the EGR and DPF items have been removed from the program. When I unplugged it, I did get a code. Not sure if that one sensor being in the program with none of the other EGR/DPF items would cause the low boost or not.
One thing I would like to know is what drives the smoke limitation #? Is there a sensor or is it calculated?
Thanks in advance!
 
Last edited:

dieselherb1

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I did the cbea swap into a 2006 Jetta, I'm having a limp mode issue also. Do you have a codes? Mine is MAP signal too high, also MAF code
 

vwztips

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2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
Sorry for the delay. No MAF or MAP issues. Finally got it figured out thanks to Mike at TDTuning. It was some background issues with some of the stuff that was deleted and Mike figured it out.

Now the TDI Tig is running great!
 

vwztips

Veteran Member
Joined
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Location
Greenville, SC
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2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
I would have to look, (should have it memorized LOL), but does the MAP and MAF share the same power supply.
 

dieselherb1

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Oct 25, 2008
Location
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06 MK5,09 Mk5 CR,03 Mk4,96,2-97 B4s,98 A3,2000 A4,4 Caddies( 2-1.6TD,1.6,TDI) Chevys 6.2,6.5,6.5TD
I'm not should about the power supply. I changed the MAP sensor today didn't help, made things worst. Now the turbo actuator pushes the vanes closed.
 

vwztips

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Joined
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2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
So have you had a tuner work on this or is everything still stock?
 

dieselherb1

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Joined
Oct 25, 2008
Location
Va.
TDI
06 MK5,09 Mk5 CR,03 Mk4,96,2-97 B4s,98 A3,2000 A4,4 Caddies( 2-1.6TD,1.6,TDI) Chevys 6.2,6.5,6.5TD
I am using a Malone stage 3 ECU also have tried a Malone stage 5.5 which is what was using with the package( CP3 pump, 3" exhaust, larger intercooler, 20/62 turbo) that I bought.
 

vwztips

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Joined
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2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
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