P2564 Turbocharger Problem?

rodstears

Member
Joined
Jul 16, 2010
Location
Saint John NB
TDI
2004 TDI
2004 PD TDI apparently a corroded and broken pin on the turbocharger is throwing a lower boost sensor code P2564. Performance seems unaffected

My questions are:

1. Is it true the plug / receptacle part of the turbo cannot be replaced and that it is built into the unit on 2004 tdi pd's resulting in a $1000 plus repair (turbocharger replacement) for the sake of one missing pin. I think I recall reading that this particular turbocharger did not allow simple plug replacement. (very poor engineering if true)

2. What affect does this code / problem have on vehicle performance. I don't seem to notice any loss.

3. Should I ignore this if entire unit needs replacement and continue to drive with this code?

4. Can this part be removed from a blown turbocharger and installed on mine?
 

turbocharged798

Veteran Member
Joined
May 21, 2009
Location
Ellenville, NY
TDI
99.5 black ALH Jetta;09 Gasser Jetta
1. Is it true the plug / receptacle part of the turbo cannot be replaced and that it is built into the unit on 2004 tdi pd's resulting in a $1000 plus repair (turbocharger replacement) for the sake of one missing pin. I think I recall reading that this particular turbocharger did not allow simple plug replacement. (very poor engineering if true)
Nope. You just need to source a new PD turbo actuator.
 

turbocharged798

Veteran Member
Joined
May 21, 2009
Location
Ellenville, NY
TDI
99.5 black ALH Jetta;09 Gasser Jetta
You were told bull crap.

Yes, they are completely replaceable. Like I said, the hardest part would be finding one. I would start hitting up all our vendors first and see if they have any in stock.

Absolutely no need to replace a 1,000 turbo for a $100 actuator.
 

rodstears

Member
Joined
Jul 16, 2010
Location
Saint John NB
TDI
2004 TDI

ianfar

Well-known member
Joined
Jul 3, 2008
Location
GTA, Ontario
TDI
05 PD Jetta - retired 2015 Jetta
When mine went I used one off a blown turbo, so I can't help there.

Have you checked your wiring to the actuator? They are known to wear anywhere between the connector and where the loom attaches to the firewall.

My wiring was bad so I fixed that only to find that the actuator was buggered as well.
 

rodstears

Member
Joined
Jul 16, 2010
Location
Saint John NB
TDI
2004 TDI
checked wiring to turbo

Yes the wiring is ok to turbo. There is a connector pin corroded and broken on the turbocharger itself.
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
How hard is it to remove this part to check? I have the same code and also thought I needed to replace the turbo...what a relief.
 

hyperhyper

Member
Joined
May 31, 2009
Location
Dittmer MO
TDI
2014 Passat TDI Manual, Malone Tuning 1.5
P2564 code

My Jetta 2004 TDI just showed the code yesterday. I was driving very slowly on a heavily potted road (1 - 3MPH). Difference was that my engine started missing badly. After I got on a good road and sped up, it started to clear some. I shut it off, reset the code with a scangauge, and it seemed to run okay. I've yet to drive it today. Are these symptoms likely a gumed up turbo and likely to come back?
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
I now have P2564 and a flashing glowplug light, brake lights are fine. Failed NJ inspection due to the CEL and them not being able to read any of my sensors, is my car in basic settings mode?

How hard is it to get the actuator off? I assume I have to get under the car to reach it. I changed my own timing belt 40k miles ago so I'm pretty sure I can fix this. Anyone gone through it?
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
Found this
http://forums.tdiclub.com/showthread.php?t=202923&highlight=p2564

My purple wire jacket is worn and the wire looks slightly corroded. I'm going to cut the wire and trim and resolder them back together, then shrink tube the wire to see if the code goes away. If it does I will order the repair wire, if not I'll replace the actuator. Will keep updates posted.
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
The actuator boraparts shows is for a Garrett Turbo, (VNT-17) not the KP39 that's on your '04. A replacement actuator for that turbo is not available. You may be able to modify the Garrett actuator to fit, but be prepared to put some effort into that. I'd be interested in how make it work. I feel badly that you can't buy the actuator for B-W turbos (BEW or BRM engines) like you can on some older TDIs.
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
The actuator boraparts shows is for a Garrett Turbo, (VNT-17) not the KP39 that's on your '04. A replacement actuator for that turbo is not available. You may be able to modify the Garrett actuator to fit, but be prepared to put some effort into that. I'd be interested in how make it work. I feel badly that you can't buy the actuator for B-W turbos (BEW or BRM engines) like you can on some older TDIs.

If it can be done I will find a way, that is if I don't find a replacement turbo for $350 or so. I can be quite creative. Will continue to post updates. Does anyone know a way to test the actuator?

If fixing the wire doesn't solve the problem I will remove the actuator and see if I can take it apart and clean it out. Anyone know how many bolts there are to take the actuator off? It looks like 2 bolts and some kind of knob the rod is threaded into.
 
Last edited:

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
Attach a vacuum pump, the actuator should start to move the lever to the turbo vanes at about 3 inches, be fully open at 12-15. It should move smoothly, and should hold the fully open position.
 

halocline

Veteran Member
Joined
Aug 13, 2009
Location
San Antonio
TDI
04 Jetta Wagon
Sounds like your best bet would be to find a blown KP39, there are probably plenty around, and swipe the actuator off of it. VW dealers sell reman KP39s so they probably send the cores in, but most independent mechanics and DIYers use new ones. So, you'll find one if you keep looking.
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
Attach a vacuum pump, the actuator should start to move the lever to the turbo vanes at about 3 inches, be fully open at 12-15. It should move smoothly, and should hold the fully open position.

If the unit were defective wouldn't I know it, my car boosts just fine and I have no spike issues. I believe the only issue with the actuator might be the electronic sensor.
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
I cut the corroded purple wire and resoldered as best I could but to no avail. I believe the wire is corroded inside the jacket further still and needs a full replacement. I didn't pull off the actuator due to not having all my tools at my disposal.

The flashing glowplug light is my new concern as I've driven the car for 6 months with the cel and no flashing glow plug light...I don't have the money to fix all this:(
 

AudiLikeA4

Veteran Member
Joined
May 26, 2004
Location
Middle Tennessee
TDI
2004 VW Golf GL Anthracite Blue Manual
I just replaced the purple wire as it was cut and corroded. I had to cut it back 12" before I found clean copper wire to solder to...Jeez.

Now I have to put the actuator I bought of a blown turbo in, but the 10mm bolts are pretty much frozen. Gonna have to soak them in PB blaster for a while and try them again. I plugged in the new actuator and put the vaccum line on and cleared the cel and it didn't come back upon multiple restarts, so I believe I will be all systems go when I finally get it in.
 

grc1234

New member
Joined
Jan 9, 2011
Location
new brunswick
TDI
2004 tdi auto 2003 tdi std
2004 jetta tdi auto. code p2564 came on. the find: connector on the sensor under the actuator was perfect, the wires at the connector was good, about 6 inches up where the 3 wires purple,green,yellow, tie into the other harness were rubbed through by the couragaded plastic jacket at the "t" of the main harness. two of the 3 wires were chaffed multiple times by the jacket. soldered in new wires heat shrink and relocated the harness of the new 3 wires. hard to find but easy fix!
 

rodstears

Member
Joined
Jul 16, 2010
Location
Saint John NB
TDI
2004 TDI
I was the original poster. I am still driving with a lower boost sensor code and all seems to be well. Been about 6 months. Still looking for an actuator.
 

halocline

Veteran Member
Joined
Aug 13, 2009
Location
San Antonio
TDI
04 Jetta Wagon
I'm going to have a KP 39 for sale pretty soon. It might be fixable; if so, it might be more than you want to spend for an actuator. If it's not, I'll sell you the actuator.
 
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