W209 220cdi limp mode

[Spyros777]

Hello all

I have read the pinned threat and pther threats but this one is a bit odd issue (see below STAR diagnostic).

So a bit of a background; I drive a w209 220cdi 2006 make. I have imported the car from UK in CY back in 2011. The car is great in overall.

The last month with my mechanic (he is a merc one/ works only on mercs) we are trying to find the culprit for the limp mode issue. The car goes into limp mode mostly on highways when I commute to work.

When the car is cold and driving around the city is mostly fine; only sometimes it goes to limp mode when I floor it. So the STAR is showing high and low boost pressure at the same time (which is a paradox). As of now, we have changed the MAF, cleaned cats, intake manifold(was leaking anyway), boost sensor and checked the intercooler lines.

We have yet to find out what is causing the issue. I repeat that the problem occurs in the highway when I floor it, when driving at the same speed constantly and when it gets up to temperature (does not overheat).

I would appreciate any input on this as I have spend quite a fortune on it now. Thank you.

 

[Spyros777]

Update: Acceleration at high rpms is jerky. The car hesitates to rev and then all of a sudden revs a lot and then the rpm fluctuate.

If any forum member here has any inputs. The car will go to my merc workshop again to check the secondary cat. DPF cleaned the first time around.

 

[Larkone]

Update: Acceleration at high rpms is jerky - when my om642 did that it was the turbo actuator failing - no codes

 

[Spyros777]

Thank you Larkone. As I mentioned, I will visit this Saturday my mechanic again and I will tell him to check the actuator. He said though last time, that in case is the actuator, this comes as a whole with the turbo. Have you changed your turbo as a whole or only the actuator?

 

[Larkone]

In the UK there is Turbo Actuator | Turbo Wastgate Actuator | Turbo Sensor who supply refurbed actuators - you just need to match the numbers. MB only supply complete turbo and actuator regardless if the turbo is OK. I only replaced the actuator and the improvement in consumption and driveability was significant. Can you not strip yours, clean the cogs and re-grease - solved my problem for about 30K miles

 

[Spyros777]

Thanks again. I asked my local MB dealership they quoted me 2.7k euros for a new turbocharger kit.

I have asked my mechanic and we do have something similar to Turbo guys you mentioned. I will update the case next week when I get the car back. Maybe I will refurb/service the current turbo as well.

 

[Spyros777]

Update: Turbo is out for servicing and new actuator. Also the intake charger hose was split (the one below). Also a new crankcase breather will go in as it some oil gets out of it.

 

[mersum1es]

Also the intake charger hose was split

That alone could have been culprit for all your problems

 

[Spyros777]

That alone could have been culprit for all your problems

The thing that troubles me though is that the hose was not actually split like in the main area/body. It was only cracked at the lip where it clamps at the housing of the turbo as well as on the other side. Would that be enough you reckon? Anyways the actuator and turbo are with a specialist for servicing. Will post an update end of next week hopefully. In any case I hope after this, the issue goes away otherwise I will think of replacement car (w213 or w205 and very remotely a 640d)

 

[Spyros777]

Update: Turbo has been refurbished and cleaned. There was carbon buildup inside and around the vanes but not too much. The actuator though was replaced as it was missing a gear tooth. Turbo was tested as well by the specialist and it is good as new. Also new inlet charger hose is going in, fresh oil and filter. I will get the car on Monday and let you know how it goes.

 

[Spyros777]

Update: git the car back with full power now.

In the end, it was the turbo actuator and the inlet charger hose.