Actuator stuck on turbo

[spartacus68]

I go for months without a fault, then my Allroad reminds me I’ve neglected it. I’ve not neglected it of course, it’s at 69k miles on a 12 plate and leads a cosseted life.

Used it today and tootling home (50 mile round trip) and the amber glow plug light comes on and starts flashing, it also went into limp mode which is a first for me. Pulled in, switched off and restarted to clear it. I’d been driving in efficiency mode, so switched to dynamic and increased my speed. A few miles later, the same error and limp mode.

Got home and scanned with VCDS. Error code is for a stuck actuator on the turbo. I’m going to double check with a vacuum pump. Anything else to check as part will be best part of a couple of hundred pounds, and I need to fit.

Wednesday, 03, August, 2022, 20:29:15:49227
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 8.1 x64
VCDS Version: 22.3.1.4 (x64) HEX-V2 CB: 0.4615.4
Data version: 20220407 DS337.0
www.Ross-Tech.com


Mileage: 111750km-69438mi Repair Order:



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 8K-AU48 (8R0)
Scan: 01 03 05 08 09 15 16 17 19 20 42 44 46 52 53 56 5F 62 69 72

Mileage: 111750km-69438miles

01-Engine -- Status: Malfunction 0010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
20-High Beam Assist. -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
53-Parking Brake -- Status: OK 0000
56-Radio -- Status: OK 0000
5F-Information Electr. -- Status: Malfunction 0010
62-Door, Rear Left -- Status: OK 0000
69-Trailer -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CGLC) Labels:. 03L-906-018-CGL.clb
Part No SW: 03L 906 018 KD HW: 03L 906 018 JL
Component: R4 2.0l TDI H25 9977
Revision: 45H25--- CVN: 45210F43
Coding: 32194012243601080000
Shop #: WSC 62265 001 1048576
ASAM Dataset: EV_ECM20TDI01103L906018KD 003004
ROD: EV_ECM20TDI01103L906018JG.rod
VCID: 76B6EF5B184B390BE53-8022
VINID: 9D196AAAA21B0144400041C720CD68878D

2 Faults Found:
9126 - Actuator Module for Turbocharger 1
P00AF 00 [101] - Stuck
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 2
Mileage: 111741 km
Date: 2022.08.03
Time: 19:37:41

Engine RPM: 1936.00 /min
Normed load value: 57.6 %
Vehicle speed: 94 km/h
Coolant temperature: 90 C
Intake air temperature: 22 C
Ambient air pressure: 980 mbar
Voltage terminal 30: 14.360 V
Unlearning counter according OBD: 40
Charge Pressure Actuator: activation: 37.37 %
Charge air pressure actuator: acknowledgment: 60.57 %
Turbocharger boost control: offset closed: -0.99 %
High press turbocharger actuator: status-Bits 0-7: 0
High press turbocharger actuator: status-Bits 0-7: 55
High press turbocharger actuator: status-Bits 0-7: 0
High press turbocharger actuator: status-Bits 0-7: 5
High press turbocharger actuator: actual uncond volt value: 2043.8 mV
Accelerator pedal travel: 42.92 %

9127 - Actuator Module for Turbocharger 1
P00AF 00 [101] - Stuck
Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 2
Mileage: 111742 km
Date: 2022.08.03
Time: 19:38:25

Engine RPM: 2823.00 /min
Normed load value: 99.2 %
Vehicle speed: 65 km/h
Coolant temperature: 86 C
Intake air temperature: 21 C
Ambient air pressure: 980 mbar
Voltage terminal 30: 14.300 V
Unlearning counter according OBD: 40
Charge Pressure Actuator: activation: 10.00 %
Charge air pressure actuator: acknowledgment: 17.00 %
Turbocharger boost control: offset closed: -0.99 %
High press turbocharger actuator: status-Bits 0-7: 0
High press turbocharger actuator: status-Bits 0-7: 55
High press turbocharger actuator: status-Bits 0-7: 0
High press turbocharger actuator: status-Bits 0-7: 5
High press turbocharger actuator: actual uncond volt value: 3437.8 mV
Accelerator pedal travel: 100.00 %

Readiness: 0 0 0 0 0

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104) Labels: None
Part No SW: 8K9 907 379 G HW: 8K9 907 379 G
Component: ESP8 quattro H09 0070
Revision: -------- Serial number: --------------
Coding: 069544
Shop #: WSC 45553 000 1048576
VCID: 46D65F9B28ABE98BB53-8012

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. (J393) Labels:. 8K0-907-064-05.clb
Part No SW: 8K0 907 064 EE HW: 8K0 907 064 EE
Component: BCM2 2.0 H10 0530
Revision: 00002001
Coding: 03B20000000000000000
Shop #: WSC 06335 000 00000
VCID: 77A8E25F1FC14003FE5-8022

Subsystem 1 - Part No SW: 8T0 959 754 D HW: 8T0 959 754 D
Component: FBSAUDIB8 IDG H60 0072
Serial number: 0811000213556019

Subsystem 2 - Part No SW: 8K0 905 852 E HW: 8K0 905 852 E
Component: J764 ELV MLB H40 0046
Serial number: 2311000300701016

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255) Labels: None
Part No SW: 8K2 820 043 AC HW: 8K2 820 043 AC
Component: KLIMA 3 ZONEN H04 0123
Revision: D0000000 Serial number: 01291220110026
Coding: 342402E080
Shop #: WSC 06335 000 00000
VCID: 6A8ECB2B5C73EDEB71B-803E

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect.
Cannot be reached
Unable to communicate with address 09. Are you sure the doors are unlocked?

-------------------------------------------------------------------------------
Address 15: Airbags
Cannot be reached

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527) Labels:. 8K0-953-568.clb
Part No SW: 8R0 953 568 Q HW: 8R0 953 568 Q
Component: Lenks.Modul H02 0171
Revision: 00000000 Serial number: 20111221000037
Coding: 000017
Shop #: WSC 06335 000 00000
VCID: 4FF87ABFC7D128C3065-801A

Component: E221 - MFL H03 0003

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285) Labels:. 8T0-920-xxx-17.clb
Part No SW: 8K0 920 982 B HW: 8K0 920 982 B
Component: KOMBIINSTR. H16 0640
Revision: 00100000 Serial number: M3B516FDC
Coding: 332529020A012600010000
Shop #: WSC 06335 123 12345
VCID: 3330164F4B396C2302D-8066

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533) Labels:. 8T0-907-468.clb
Part No SW: 8R0 907 468 D HW: 8R0 907 468 D
Component: GW-BEM 5CAN-M H10 0025
Revision: 1Z070014 Serial number: 1441Z11B170022
Coding: 00CF07FF00
Shop #: WSC 06335 000 00000
VCID: 40DA49830A8FC7BB8FF-8014

Subsystem 1 - Part No SW: 8T0 915 181 HW: 8T0 915 181
Component: J367-BDMHella H03 8040
Serial number: 2248456201

Subsystem 2 - Part No SW: 8K0 959 663 HW: 8K0 959 663
Component: J532_DCDCStab H17 0042
Serial number: 11349000532021200181

No fault code found.

-------------------------------------------------------------------------------
Address 20: High Beam Assist. (J844) Labels:. 8K0-857-511.clb
Part No SW: 8T0 857 511 AD HW: 8T0 857 511 AD
Component: FLA H04 0012
Revision: AA001002
Coding: 02029164747464545425363E00
Shop #: WSC 06335 000 00000
VCID: 7CA2FD7326E7635B937-8028

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386) Labels:. 8K0-959-793.clb
Part No SW: 8K0 959 793 P HW: 8K0 959 793 P
Component: TSG FA H02 0506
Revision: Serial number: 0000019924132
Coding: 011C02204001410001
Shop #: WSC 06335 000 00000
VCID: 4DC460B7CDDD1AD3749-8018

No fault code found.

-------------------------------------------------------------------------------
Address 44: Steering Assist (J500) Labels:| 8K0-909-144.clb
Part No SW: 8K0 909 144 F HW: 8K0 909 144 B
Component: RCEPS H36 0507
Revision: 00001000 Serial number: 0018275610
Coding: 100000010001
Shop #: WSC 06334 000 00000
ASAM Dataset: EV_RCEPSAU48X 008014
ROD: EV_RCEPSAU48X_008.rod
VCID: 343215534EB76B1B1B7-8060

No fault code found.

-------------------------------------------------------------------------------
Address 46: Central Conv. (J393) Labels:. 8K0-907-064-46.clb
Part No SW: 8K0 907 064 EE HW: 8K0 907 064 EE
Component: BCM2 2.0 H10 0530
Revision: 00002001 Serial number: 0165755902
Coding: 013B062220B900548020023680000000
Shop #: WSC 06335 000 00000
VCID: 77A8E25F1FC14003FE5-8022

Subsystem 1 - Part No: 8K0 951 177
Component: DWA-Sensor H02 0040

Subsystem 2 - Part No: 1K0 951 605 C
Component: LIN BACKUP HO H05 1501

Subsystem 3 - Part No SW: 8K0 959 591 B HW: 8K0 959 591
Component: J245 PS150 H08 0043

Subsystem 4 - Part No SW: 8K0 959 591 B HW: 8K0 959 591
Component: J394 PS240 H08 0043

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387) Labels:. 8K0-959-792.clb
Part No SW: 8K0 959 792 P HW: 8K0 959 792 P
Component: TSG BF H02 0506
Revision: Serial number: 0000019936511
Coding: 011C02204401410001
Shop #: WSC 06335 123 12345
VCID: 4CC26DB336C713DB637-8018

No fault code found.

-------------------------------------------------------------------------------
Address 53: Parking Brake (----) Labels: 8K0-907-801-V2.clb
Part No SW: 8K0 907 801 J HW: 8K0 907 801 J
Component: EPB-4 H01 0001
Revision: -------- Serial number: 30000000009839
ASAM Dataset: EV_ParkiBrake 001022
ROD: EV_ParkiBrake_AU48.rod
VCID: 36362F5B58CB790B253-8062

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio (R) Labels:. 4F0-035-0xx-56.clb
Part No SW: 4G0 035 061 S HW: 4G0 035 061
Component: Radio U DAB H60 0154
Revision: AB001007 Serial number: 109L30B7541767
Coding: 010103020100000001
Shop #: WSC 06335 000 00000
VCID: 2D040037AD1D3AD3549-8078

No fault code found.

-------------------------------------------------------------------------------
Address 5F: Information Electr. (J794) Labels:. 4E0-035-6xx-5F.clb
Part No SW: 8R2 035 666 L HW: 8R2 035 666
Component: H-BN-EU H43 1036
Revision: -------- Serial number: 066L20B7506178
Coding: 10010105000681ED0580AB5E00000403E40000020000000000
Shop #: WSC 45553 000 1048576
VCID: 42DE438B0483D5AB99B-8016

Subsystem 1 - Part No: 8R0 060 884 GS
Component: EUR 2020 3001

Subsystem 2 - Part No SW: 8R0 919 604 HW: 8R0 919 604
Component: DU7 High H41 0104
Serial number: A130LD0BS081781

Subsystem 3 - Part No SW: 8T0 919 611 K HW: 8T0 919 611 B
Component: E0380 Bedient H02 0030
Serial number: 00000001025324

Subsystem 4 - Part No: 8R0 060 961 C
Component: CD-Database 3638

1 Fault Found:
03623 - Invalid Security/Release Code
000 - -
Freeze Frame:
Fault Status: 01100000
Fault Priority: 6
Fault Frequency: 1
Reset counter: 59
Mileage: 111683 km
Time Indication: 0
Date: 2022.07.07
Time: 15:18:00

Freeze Frame:
Hex Value: 0x0004
Hex Value: 0x000B
Count: 6


-------------------------------------------------------------------------------
Address 62: Door, Rear Left (J388) Labels:. 8K0-959-795.clb
Part No SW: 8K0 959 795 D HW: 8K0 959 795 D
Component: TSG HL H01 0506
Revision: Serial number: 0000019919468
Coding: 010C02204001210001
Shop #: WSC 06335 000 00000
VCID: 43D0468F1B99DCA392D-8016

No fault code found.

-------------------------------------------------------------------------------
Address 69: Trailer (J345) Labels:. 8K0-907-383.clb
Part No SW: 8K0 907 383 E HW: 8K0 907 383 E
Component: Anhaenger H09 0100
Revision: 1A001001 Serial number: 00000181546479
Coding: 0100000000000000
Shop #: WSC 00000 000 00000
VCID: 36362F5B584B790B253-8062

No fault code found.

-------------------------------------------------------------------------------
Address 72: Door, Rear Right (J389) Labels:. 8K0-959-795.clb
Part No SW: 8K0 959 795 D HW: 8K0 959 795 D
Component: TSG HR H01 0506
Revision: Serial number: 0000019919465
Coding: 010C02204001210001
Shop #: WSC 06335 000 00000
VCID: 43D0468F1B99DCA392D-8016

No fault code found.

End----------(Elapsed Time: 01:49, VBatt start/end: 12.0V/12.0V)-----------

 

[spartacus 68]

Update to this. Called Audi - and they don't even supply the actuator, all they will sell is the full turbo at £1k. The turbo which apparently only fits two models is 03L145721B and fits just two models - CGLC/D engines (177PS).

I can see the actuator on the turbo and suspect it can be sourced as a separate part? Quick check on Autodoc reveals actuators from Meat & Doria, Fispa and Sidat. I'm not familiar with these manufacturers other than Garret for turbos - which I think would be the original supplier?

Is it false economy to fit just the actuator, or would you plump for a new turbo? I'm not going down refurbished route. I've seen a new Garret turbo for £520 that comes with 24 month warranty Obviously that's part only, not fitting, which could be a bit of a pig to fit with exhaust manifold, etc.

This picture shows the actuator in place. https://www.partshaus.co.uk/products/audi-a4-a5-a6-q5-2-0-tdi-garrett-turbo-turbocharger-03l145721b

Finally - would the turbo need any coding, or is it simply clear codes connect electrics and drive?

 

[Darren92]

Replacing the actuator is fine, though it needs adjusted and monitored with VCDS or some other diagnostic equipment afterwards to ensure the correct values. Leave the car to a turbo shop to have it replaced and calibrated.

 

[spartacus 68]

Update to this. I stripped out the air box to take a closer look At the weekend. The actuator is set up as part of the turbo. Now it could the actuator has failed (vacuum test will confirm), but more likely result of carbon deposits in the turbo not releasing the actuator rod.

After watching countless videos, the only way to get the actuator off is to strip out the turbo. If going to the bother of that, then it makes sense to swap out the turbo too. Still waiting on a refurbished Garrett quote. They take the old turbo back to as part of the swap.

I have seen actuators swapped, but it needs to be set up on the turbo at full vacuum, then the voltage to the signal wire as I understand it at 0.75 volt or you can get a position error code.

 

[spartacus68]

 

[spartacus68]

Latest update. New Garret turbo has arrived. £400 cheaper than Audi. Just waiting on gasket kit.

 

[spartacus68]

Got the car fixed by a local indy. Not bad for £260 for 4 hours labour, but I supplied new turbo at £550 +VAT, Elring fitting kit from Germany, another £24, new oil filter and sump plug from Audi, £18 and 5 litres of Castrol Edge 5w30, £45.

I can recommend https://turbo-diesel.co.uk/ for the turbo. Genuine new Garret turbo straight from the factory. Good communication, although despatch time was a bit of a wait. I plan to strip down the old turbo and test the actuator and will post up pictures. It can go on the shelf in the garage if it fails again in another 70k miles.

 

[spartacus68]

Turbo stripped down. Some interesting discoveries.

1/ The turbo didn't have a huge amount of carbon build up, and importantly the vane mechanism moved okay before it was cleaned. There was a little corrosion on turbo body behind the second turbine from air intake.

2/ I've still to test actuator as I don't have a vacuum pump.

3/ This has me puzzled, on the first turbine at the air intake side, one of the turine blades was bent? I tried to straighten with needle nose pliers but snapped.

Video of the turbo vanes. https://youtube.com/shorts/E7PbZcsSjMI?feature=share

More pictures here and after cleaning.

 

[spartacus68]

Another pictures of it cleaned. Note the damage to the blade.

 

[audiwaterpump]

Turbo stripped down. Some interesting discoveries.

1/ The turbo didn't have a huge amount of carbon build up, and importantly the vane mechanism moved okay before it was cleaned. There was a little corrosion on turbo body behind the second turbine from air intake.

2/ I've still to test actuator as I don't have a vacuum pump.

3/ This has me puzzled, on the first turbine at the air intake side, one of the turine blades was bent? I tried to straighten with needle nose pliers but snapped.

Video of the turbo vanes. https://youtube.com/shorts/E7PbZcsSjMI?feature=share

More pictures here and after cleaning.

If Carlsberg did forum posts.... thanks for keeping us up to date.

"one of the turbine blades was bent?"
That could only happen if something struck it and then disintegrated, which may be related to your original fault.

Can only

 

[spartacus68]

If Carlsberg did forum posts.... thanks for keeping us up to date.

I‘ll take that as a compliment!

Good fun stripping it down. It’s probably toast with that damaged turbine even although it’s all cleaned up and reassembled. I’ll hold on to it, if it goes Pete Tong in another 70k miles at 20 years old I’ll stick it back in.

 

[audiwaterpump]

Would be interesting to know what could have got in there and bent that blade.
Don't know much about turbos but the air entering the turbo is that filtered?

Your guesses/speculation.

 

[spartacus68]

No idea regards what could bend the turbine blade. It was just the one blade, and there’s no evidence of any other damage. The air is filtered (stock filter) but that said I’ve removed the air filter and vacuumed the area directly below and the odd wasp or fly seems to have made it though from the air intake but not past the filter. The filter is generally clean, and I’m not driving in dusty area. I also can’t see the mechanic damaging it when it was removed, as it’s a rubber hose and clip on the inlet side, so nothing to lever off, but never say never.

Given the work involved to replace the turbo, it would be daft to replace it with this one if it ever failed again. My understanding is turbos are bench tested and the turbine would be balanced once they are built, given the turbo spooling speed and temperature. If I still have the car in another 10 years and diesel isn’t the same price of Bollinger champagne I’ll go for a rebuild Garrett unit and send them this one as a surcharge.

 

[audiwaterpump]

One can only assume it must be Uri Geller or the mechanic


If it's happened once under ^normal" operating conditions, then it may happen again.