MK4 Golf low boost then limp problem (with log)

rob136

Member
Joined
Jan 1, 2015
Location
Birmingham
TDI
mk4 golf TDI
Hi All,
This may be a bit of an essay but I want to get as much info in as possible!

the car is a 2003 mk4 golf pd100 with remap done a year and a half ago (by awesome gti). In the recent months I thought I noticed it occasionally not pulling quite as hard as it should however this was very minor and could well have been just in my head!

I decided to fit an EGR delete pipe (egr already coded out with remap) approx. 2 months ago. at the same time I did the vac simplification using new pipes following the guide http://uk-mkivs.net/topic/50427-pd-vac-line-simplification-n18-n239-valve-delete/. As I planned to go for more power I used a pd130/150 delete pipe and fitted the manifold with it. (bigger than the pd100).

Since then the car has had very little power low down only coming on boost at 2200rpm. in 4 or 5th gear when driving it hard it will go into limp over about 3k rpm. It also throws out quite a lot of black smoke until the boost comes in. MPG has dropped from an average of about 54 to about 45. With the limp mode it throws up fault code
17964 - charge pressure control p1556-35-10 - Negative Deviation - Intermittent.

I have since added a PD130/150 turbo intake pipe MAF and airbox (not to cure the issue but because the 100 does not fit properly with the 130 manifold.) This has obviously not cured the issue although black smoke does seem reduced.

Doing some more diagnosis I found the turbo VNT does not move when checked using basic settings 11 in VCDS. It moves fine b hand and if I take the hose of the n75 I can easily suck the turbo fully open using my mount. (haven't got a vacuum gauge currently the check pressure). I did try blocking the hose with the vnt sucked down and the boost returned (I was carful here not to push the car and cause overboost!).

I tested the resistance of my on n75 valve and it was 16 ohms which after some online research was out of VWs spec of 25 to 35. I brought a new one from darkside and fitted it today and it makes no difference to the car. I did check the resistance and it was 15.6 ohms which got me wondering whether the new n75 is also faulty or whether I have found incorrect info on web or maybe even my ohm meter is faulty (it is only a cheapy maplin one). I have also tried swapping the egr solenoid and again no difference to car.

I have now done a quick log of block no 11 and was wondering if anyone can suggest what to check next to restore power. the duty cycle in the log seems a bit all over the place to me but to be honest this is the first time I have used vcds logs so Im not fully sure yet what they mean!

 

BobnOH

not-a-mechanic
Joined
May 29, 2004
Location
central Ohio
TDI
New Beetle 2003 manual
No codes?
Check to see if the actuator engages the vanes at start-up. If they don't check vacuum supply
 

rob136

Member
Joined
Jan 1, 2015
Location
Birmingham
TDI
mk4 golf TDI
the vnt doesn't move on start up no. The vac pump works fine and brakes ect are perfect and I've checked for any servo pipe leaks. The code its throwing is 17964 as above. My thoughts now are to power the n75 directly and see if that then allows the actuator to move. I have checked the vac lines and they are all new but I will take them all of again and double check for blockages ect.
 

rob136

Member
Joined
Jan 1, 2015
Location
Birmingham
TDI
mk4 golf TDI
Done some more testing today and found the following:

If I connect the vnt actuator direct to the servo vacuum pipe with a T piece in the middle the turbo moves fully and freely when I block the T piece.

All vacuum pipes are clear of blockages and damage.

The n75 valve works correctly when connected directly to the car battery.

I unplugged the n75 whilst the car was running then when I plugged it back In the VNT moved to the stop and back.

All this is making me wonder whether it is a mapping issue? I cant believe though that the addition of a PD150 manifold is creating enough extra space for the turbo to fill to cause this amount of lag and low boost fault codes?
 

rob136

Member
Joined
Jan 1, 2015
Location
Birmingham
TDI
mk4 golf TDI
Well just had a brain wave and its all fixed! disconnected the N75 and ran a fault scan and it threw an EGR fault! Bingo!


Yes The N75 was fitted where the EGR valve should go. swapped over and shes good as new! Feel like a bit of a numpty now considering how many times ive had these on and of before and not put them if the wrong places but at least its sorted now!
 

Raweaver_410

Active member
Joined
Jan 16, 2014
Location
Cordova, MD
TDI
Mk4 Silver Golf TDI 5spd, Mk4 Red 2.0 Jetta Auto, Mk2 Blue Diesel Jetta 5spd, Mk1 Sandy Diesel Jetta 5spd
Well just had a brain wave and its all fixed! disconnected the N75 and ran a fault scan and it threw an EGR fault! Bingo!


Yes The N75 was fitted where the EGR valve should go. swapped over and shes good as new! Feel like a bit of a numpty now considering how many times ive had these on and of before and not put them if the wrong places but at least its sorted now!
As I was reading this I was just thinking you hooked the connectors up wrong because I have mistakenly done the same thing (all the connectors look the same) I realized what I did as soon as I drove the car though haha.
 
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