Turbo help

[mdelfunt]

Hey guys,
I have a 2008 Bluetek w/200k miles that's been performing poorly and need some assistance. First a little background:
CEL persist and going into limp mode. Recycle the key and it runs fine for a few miles and then problems resume. I had multiple codes including downstream O2 sensor (which I replaced), 2598-001 EGR positioner fault (which I replaced), 2944-004 Glow plug 3 (haven't replaced yet). After replacing the EGR I started getting 2355-001 EGR Air mass too low. While no longer going into limp mode, it started jerking during acceleration almost every time I cranked it up but then seemed to stabilize after running for a while. The RPM's of the engine matched the jerking. Mileage is low - 20MPG.
All of this led me to suspect intake manifold plugging and Swirl flaps.

I took the intakes off yesterday to clean them (and replace the oil cooler and Swirl motor while out) and started questioning whether the Turbo was acceptable or not. There's NO sign of the vanes hitting the sides of the housing and it has a little play in it when I attempt to push the vanes to either side. When I acquired the car I was told be the owner that the Turbo had recently been replaced though no way to know for sure. So I'm going to start the clean-up process on the intakes but I wanted to get peoples thoughts on the Turbo possibly being bad. I would rather replace it now that a month from now even though its going to cost me $1300. BTW, one of the exhaust bolts on the Turbo broke off in the Turbo when removing. So if I keep this one I have to do an extraction (fun fun).

What are your thoughts and thank you so much!

 

[Spyros777]

Hello! Check also the turbo actuator. Mine was faulty and I replaced it along with a turbo refurb while it was out of the car.

Had the similar limp mode issue; cleaned the cats, egr, changed sensors, fuel filter, changed the inlet manifold etc only to find out that it was the turbo actuator.

Hope it helps!

 

[mdelfunt]

Hello! Check also the turbo actuator. Mine was faulty and I replaced it along with a turbo refurb while it was out of the car.

Had the similar limp mode issue; cleaned the cats, egr, changed sensors, fuel filter, changed the inlet manifold etc only to find out that it was the turbo actuator.

Hope it helps!

Thanks for the input Spyros777. I changed the turbo actuator a couple years ago but its possible its bad. I will change it to be sure while I've got it all torn down.

In the disappointment column, there are likely people who has more guidance on this but it seems this forum has too little activity. I really needed help assessing the condition of the Turbo b/c its a big purchase if it is.

 

[Spyros777]

Thanks for the input Spyros777. I changed the turbo actuator a couple years ago but its possible its bad. I will change it to be sure while I've got it all torn down.

In the disappointment column, there are likely people who has more guidance on this but it seems this forum has too little activity. I really needed help assessing the condition of the Turbo b/c its a big purchase if it is.

Hope you sort it out. Let us know how it goes!

 

[W1ghty]

Thanks for the input Spyros777. I changed the turbo actuator a couple years ago but its possible its bad. I will change it to be sure while I've got it all torn down.

In the disappointment column, there are likely people who has more guidance on this but it seems this forum has too little activity. I really needed help assessing the condition of the Turbo b/c its a big purchase if it is.

Before you change the turbo I would consider the following .
Change the exhaust back pressure sensor £60 to the right of the turbo .( Or spray clean the small hole on its underside which can clog with gunk )
Fit a 4.7k ohm resistor into the middle 2 terminals of the inlet port(swirl flap motor) electrical supply .(Google om642 resistor fix for more info) . Cost £2 .
There is a 15 amp fuse in the engine bay fuse box that covers the egr,inlet port motor,back pressure sensor and turbo. This can cause a fault on one to look like it’s coming from another as they are all connected . Change the fuse Cost £1 .
Spray clean the since of the turbo actuator with electrical cleaner and put some high temp grease on the worm gear …just a tiny amount .
spray some turbo cleaning spray through the front of the turbo .

 

[mdelfunt]

Before you change the turbo I would consider the following .
Change the exhaust back pressure sensor £60 to the right of the turbo .( Or spray clean the small hole on its underside which can clog with gunk )
Fit a 4.7k ohm resistor into the middle 2 terminals of the inlet port(swirl flap motor) electrical supply .(Google om642 resistor fix for more info) . Cost £2 .
There is a 15 amp fuse in the engine bay fuse box that covers the egr,inlet port motor,back pressure sensor and turbo. This can cause a fault on one to look like it’s coming from another as they are all connected . Change the fuse Cost £1 .
Spray clean the since of the turbo actuator with electrical cleaner and put some high temp grease on the worm gear …just a tiny amount .
spray some turbo cleaning spray through the front of the turbo .

Thank you W1ghty.
I'm going to replace the Backpressure sensor while I've got it all torn apart.
I made a decision to do a Turbo cartridge rebuild kit instead of replacing the whole thing... much more economical.
I was able to remove the broken bolts from the Turbo without damage.
I have a new swirl flap motor coming so I don't need the resistor at this stage.
I've cleaned up the intake into the heads and Intake manifolds - what a messy job!
When my gasket kit gets here, I'll be ready to put it back together.

 

[Spyros777]

Hope you sort it out. Let us know how it goes!

Strangely enough, got the limp mode on the high way this morning . Had to pull over to turn off and restart the car. The car does this when i floor it to pass another car and thenNo acceleration at all. No check engine or nothing yet. Hopefully the mechanic will find the issue swiftly.

 

[mdelfunt]

Strangely enough, got the limp mode on the high way this morning . Had to pull over to turn off and restart the car. The car does this when i floor it to pass another car and thenNo acceleration at all. No check engine or nothing yet. Hopefully the mechanic will find the issue swiftly.

So sorry
I assume you don't have a scanner?

 

[Spyros777]

So sorry
I assume you don't have a scanner?

Its okay, these things happen. Unfortunately I dont have scanner :/

 

[Spyros777]

Car diagnosed today with STAR and no error was found. My mechanic said to keep driving it until the check engine light comes up.

Btw dod you fixed yours?

 

[mdelfunt]

Car diagnosed today with STAR and no error was found. My mechanic said to keep driving it until the check engine light comes up.

Btw dod you fixed yours?

Still working on it. Waiting on a Turbo rebuild cartridge. Most everything else is completed.