What should I do, Limpmode with codes and long story..

[Rasmus]

Could write a book about my story but here is the "short" story.

Got a A4 3.0 Tdi Manual ,Engine code CAPA, 65k miles, licens plate ART759 for more specs at car.info .Bought it 1,5 years ago, lovely car.
This summer I decided to get a stage 2 done to it.
The DPF was replaced with a 3" downpipe, K&N Airfilter, Egr software delete and a "individual" tune. Not a remapp just a adapted stage 2 software, thats what all tuners call it here.
Dynapack bench showed 256whp and 660nm.
All was working fine and I have never had a enginelight during the 1 year I drove it befor stage 2 uppgrade.

The first time the problem appeared was at 135mph. Car lost power and glow plug light was flashing.
Stoped car by the side of the road and after 5 minuters waiting I turn the car back on and it worked perfect.
Since then the speed when this problem reappeared has been lowered. Now att 85mph the car goes into limpmode when I hit full throttle.

I have had it to 4 auto repair shops! 4...
First shop looked for leaks and greased the acuator and could not find anything wrong.
The saw a fault code P0234 "turbo overboost condition" which I already told them cause I have a generic fault code reader.

Second repair shop was the tuners. Didnt go to them first because its a long drive.
They also didnt find anything wrong with the tune or the hardware.
The told me to go to a authorised Audi repair shop. ( I got my money back from them be assured)
At the third repair shop the car was undertaken by a Audi specialist that acording to the staff was the 3rd best in Sweden. ( looks like they dont know **** here)
They found nothing wrong with the car and since its been optimized they didnt really want to touch the car.
Same place told me its impossible to fit the S4 brake caliper onto a A4.
For the fourth repair shop I drove a couple of hundred miles to reach. They have multiple shop around the country and got good reviews from Audi owners.
After 2hours I got the car back with their Stage 2. The tuner said that previously tune was set at 1.95 bar and he turned it down to 1.80 bar since the stock map sensor is maxed out at 2 bar.
On the way home the same flashing glow plug light emerges under same cirkumstances as befor.
2 of the repairshops hav detached the actuator on the turbo side and it moved freely.
Noone have noticed any malfunctioning hardware.
New software and still same problem.
By the time a got home the rear parking sensor stoped working, the oil level was unreadable in the display, door light fault code, headlight fault code , 01314 fault code, xenon light range sensor fault code, cd player fault code, dynamic shock absorber, wiper switch, etc etc about 20-25 fault codes. Almost burnt down the garage with the car in it so tired of the car not working properly.

So. I cant turn the car in at a repair shop and say " just fix this" because they will scam me into changing every part of the car befor trying to sell me a new car. Its faoul and corrupt here.
I need to know what should be done and then order that specific job to be done or I might just as well give them 15.000£ for everything they gonna want me to replace.

I wanted to change the acuator but apperantly noone of the 10 million people living here have ever done that befor.

Anyone have a possible solution?

 

[Seanchadwick2k3]

Can't comment on your over boost but I'm sure when my car was mapped it flagged all sorts of errors up. Clear them and they shouldn't come back.

 

[Rasmus]

Can't comment on your over boost but I'm sure when my car was mapped it flagged all sorts of errors up. Clear them and they shouldn't come back.

I forgot to write that when cleared they dont appear again, samt as in your case.
Except for my nemesis p0234..

 

[Seanchadwick2k3]

Have you had the actuator stop screw checked? I've read that if you mess with that it won't boost properly. Also have you logged requested boost Vs actual with vcds or similar?

 

[RS4B5]

Get the mapped sorted as it looks like that's the culprit I've had both 2.0 TDI and 3.0 TDI with po234 your vanes in the turbo are clogged what fuel do you use???

 

[RS4B5]

You is it a smokey map

 

[Rasmus]

Have you had the actuator stop screw checked? I've read that if you mess with that it won't boost properly. Also have you logged requested boost Vs actual with vcds or similar?

Honestly I dont know alot about engines, I can maybe install a new airfilter and disconnect the battery. So with that said I am a easy victim for the repair shop as my knowledge is based on online reading.

I have looked under the hood and I found about 20-30 green and blue spots made with a penn so maybe 1 or 2 of the repair shop have checked alot of the stuff under the hood.

The tuner that gave me the stage 2 software also installed the 3" downpipe. Is it possible they removed the turbo for that installation and then somehow didnt set the actuator screw in the right place? It was after that visit the fault started.

I havent logged the boost, the only thing I know is what the last tuner said and that was that during the testdrive befor my latest stage 2 software the recorded a max boost reading at 1.95bar and that was in his opinion to aggressive so the new limit was set at 1.80bar.
He told me he could code away the fault code so it wont send car into limp mode when it get up to max boost. We decided not to because if the turbo would malfunction and go haywire I wont know until something breaks under the hood.

On a other forum someone ask the question if it could be so that the tuners have forgot to code away the turbo preassure warning and that it could be the problem since noone have detected any hardware related problems.

What do you think about that?

I dont have acces to a vcds sadly and repair shop charge 150£ just to read codes.

 

[Rasmus]

Get the mapped sorted as it looks like that's the culprit I've had both 2.0 TDI and 3.0 TDI with po234 your vanes in the turbo are clogged what fuel do you use???

Hi, how can I get my map sorted,
Is a custom map the only way?
It cost alot to get that done.. roughly something like this pricelist. First software 500£, starting fee for mapping 110£, 4 hours of mapping 450£, extra fee for every hour exceeding 4h is 125£ per hour. We talk about atleast 1100£ and a 8h drive front and back.
And if something dont work properly they have to repair/replace it on the spot and in that position they can charge whatever they want.


Can the VNT vanes be checked without have the turbo removed?
I thought the vanes was checked by some workshop but if the case is that it have to be removed and dissembeled to be checked then maybe that would be something to try.
A repair shop will charge around 3h of labor for that task if they are up for it. Thats around 250£ for a local none authorised repair shop.
A brand new turbo unit with actuator is around 630£ when you send your old turbo in return.

 

[Rasmus]

You is it a smokey map

I have nothing to compare to but it does not come black/dark smoke either on idle or full throttle.
I did one time park close to the wall in the garage and told the missis to hit the throttle while I looked at the actuator under the hood and the actuator moved as she pressed the throttle. After that I got two 7 inch black round spots in the wall. Yay

 

[RS4B5]

The smokey bit is caused by the map it might need turning down p0234 is your turbo unless you have a boost leak the only way to check vnt is taking it off mine were clogged on both cars try running turbo forte cleaner and give it a good boot what fuel do you use

 

[Rasmus]

The smokey bit is caused by the map it might need turning down p0234 is your turbo unless you have a boost leak the only way to check vnt is taking it off mine were clogged on both cars try running turbo forte cleaner and give it a good boot what fuel do you use

Can it run totally smoke free? I have no DPF. The smoke aint visible i think but some black sot can be found on the exhaust tip, thought it was normal.
What possible things can cause boost leak? Anywat to find it, any tubes to check or spray smoke to see if something aint right or any tricks to do to se if something aint right. Like disconnect a vacum hose to see if it will suck or disconnect the MAF to see if car runs better without. How hard is a removal/cleaning of turbo to someone that never have done some work on a car?
The fuel is Diesel.. I fuel the car at diffrent gas stations but maybe most frekvent on ST1. Will try to attach a image of data on the fuel.

 

[RS4B5]

Try the turbo cleaner and a tank if vpower

 

[briceportier]

I've got the same issue (i.e. limp mode) almost each time I go for a long drive. And stopping for a couple of minutes, if that long, is indeed enough for the car to run correctly...
And the verdict is: EGR valve
This was confirmed by the dealership where I get the car serviced but I couldn't get it changed under warranty re the dieselgate software update (known to increment the failure rate/frequency) because 7the first instance of the issue actually occurred before the update.

As for the errors get an OBDII reader as well as well as say carista...

Sent from my SM-G965F using Tapatalk

 

[Rasmus]

Try the turbo cleaner and a tank if vpower

How many hours of labor is reasonable for a repair shop to charge me for if I order a turbo VNT clean job?

Can you be so kind to post a link to the turbo cleaner?

After some reading so here i sweden we dont have a v-power diesel and the reason for it according to Shell is there are to few diesel cars.. so I can only get regular diesel here.

 

[Rasmus]

I've got the same issue (i.e. limp mode) almost each time I go for a long drive. And stopping for a couple of minutes, if that long, is indeed enough for the car to run correctly...
And the verdict is: EGR valve
This was confirmed by the dealership where I get the car serviced but I couldn't get it changed under warranty re the dieselgate software update (known to increment the failure rate/frequency) because 7the first instance of the issue actually occurred before the update.

As for the errors get an OBDII reader as well as well as say carista...

Sent from my SM-G965F using Tapatalk

Hi
Did your limpmode occur in the same way as for me? I can drive for long but if a try to max out 4th gear and higher I get limpmode.
My EGR is decoded in the software so any problem with it shouldnt cause problems with the car I guess but dont know for sure.
Do you know what faultcode your car got?
I have a fault code reader already as I wrote in my first text. Its a generic on suitable for Audi, vw,skoda called Icarsoft. Nowhere near as good as a vcds but I can read and delete codes etc.

 

[RS4B5]

Forte turbo cleaner if it doesn't work don't clean it replace it don't you have Premium diesel

 

[RS4B5]

http://rover.ebay.com/rover/1/710-5...okGKii-5Bpol2nbgQOO62DuO0fRNhktcaAhzTEALw_wcB

 

[Rasmus]

Forte turbo cleaner if it doesn't work don't clean it replace it don't you have Premium diesel

I found this, do you think it works as well?
1st one works around multiple parts of the engine and the 2nd one is a more powerful cleaner that works with VNT turbos.

https://www.josema.se/product/extrem-dieselsystem-rengoring-jlm-diesel-extreme-clean

https://www.josema.se/product/turbo-cleaner


Sound like a plan, use some turbo cleaner and replace turbo if it dont work.


Nowhere in sweden can premium diesel be found. Not enough dieselcars they have said I saw somewhere and also something about enviroment regelations.
U can however get v-power petrol but its not the same as in other countrys, they have added more E85 in it here. Its not many gas stations that have V-power maybe 100 in totalt

 

[RS4B5]

V power petrol = higher octane
V power diesel = cleaning additives inside

 

[Rasmus]

Update

I have used both of the additives, the extreme clean and the turbo clean and I have driven 1000Miles.
The problem still occur.
Have managed to get the car to 140mph a few times but almost everytime I but the 6th gear in and give full throttle the car goes into limpmode.

A few questions.
1.
How long does a repairshop need to do a complete turbochange? Ive have offers from 350£ to 600£ from the shops which is confusing.

2.
Is it possible to remove and dissemble the turbo on my own to clean the VNT and install it again or is any special tools/programming needed?

3.
As if this problem isnt enough my xenon range sensor is broken.
New one id one the way.
But. I got a "suspension system fail" error now.
And since I got dynamic steering the shock absorbers are filled with air and very expensive, and needed to be changed in pair. Repairshop said they cost 3000£ for the pair.
Can the suspension system fail be a part of the faulty xenon range sensor?

4.
Where from can I find a list of parts that match 100% with my car?
Cant find shock absorbers anywhere..

Thx

 

[Rasmus]

Update!

I replaced the turbo and the car works again!
Have been working fine for 10 days and tested high speed runs.

Today I got into limp mode again. (FML banging my head at the wall)
Full throttle at 3rd gear and got limpmode all the way home.
Codes say P008700 Active/static Fuel Rail / system Pressure - Too Low

What is requied to do now.. Is a new Fuel pump what I need?
Starting to hate my car.
Yes I drive it like a motherfucker.
Will a S4 hold up better?