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Author Topic: stumbling, erratic idle, low power, revs limited 2000rpm  (Read 9965 times)

Offline harpster

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stumbling, erratic idle, low power, revs limited 2000rpm
« on: April 10, 2012, 11:32:54 PM »
hi
 
 History - car had tons of white smoke last week Compressor wheel had damage and too much play in the shaft, turbo seals failed!!!
 i have since, replaced with a new turbo and oil feed pipe, air and oil filter oil change, flushed all pipework and intercooler cleaned out inlet manifold, replaced new egr,cold temp sensor as i had inlet manifold off, triple dose of millers additive in the fuel filter to help clear injectors (just incase) and fitted a new Cat. Mass meter reading are coming back as good when car is up to speed and map.
The issue i am still having is that the car will not accelerate in 1st it is upto 10mph and 2nd gear 15mph(really bogged down pulling back, revs stay low with speed, vcds shows throttle being pressed 100%) unless i rev it up by dabbing the accelerator until over 1600rpm, and then it goes, but when the turbo kicks in 1800rpm ish it shoots.
Revs and speed stay the same so not a clutch issue.
It does not accelerate in higher gears too, unless revs are over 2000rpm while the turbo is kicking in.
It is not smoking at speed only when idle (black puffs here and there),
The other thing i have noticed is it will not rev over 2000rpm while stationary.
When parked in neutral starts to shake rev counter showing 842 to 942 rpm at idle or it shakes at 2000rpm violently with puffs of black smoke.
I have noticed if i accelerate really slowly at idle it will rev up past 2000rpm.
i have also now ordered a n75 boost valve, but the old one seems fine as i have had it off and put 12v to it and it clicks. 
 also what makes it worse no fault codes are showing up...except brake light switch, which has been on it for a year.
hear is a graph of group 3,10,11

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #1 on: April 10, 2012, 11:37:13 PM »
Code: [Select]
Group A: '003
Engine speed MAF (specified) MAF (actual) EGR duty cycle
TIME 820-900 230-420 230-420 10-95%
STAMP /min mg/str mg/str %
0.38 1827 850 754.6 4.8
1.46 2016 850 744.8 4.8
2.6 2226 850 1146.6 4.8
3.72 2583 850 1249.5 4.8
4.82 2898 850 1210.3 4.8
5.92 3192 850 1249.5 4.8
7.04 3507 850 1205.4 4.8
8.16 3801 850 1161.3 4.8
9.24 4053 850 1136.8 4.8
10.32 2877 250 882 4.8
11.42 2814 250 705.6 4.8
12.54 2751 250 671.3 4.8
13.66 2688 250 676.2 4.8
14.78 2625 250 676.2 4.8
15.92 2562 250 656.6 4.8
17 2499 250 661.5 4.8
18.1 2457 250 651.7 4.8
332.43 1743 850 749.7 4.8
333.53 1932 850 1249.5 4.8
334.58 2247 850 1166.2 4.8
335.69 2562 850 1185.8 4.8
336.79 2898 850 1249.5 4.8
337.87 3171 850 1249.5 4.8
338.97 3444 850 1215.2 4.8
340.09 3696 850 1171.1 4.8
341.24 3927 850 1136.8 4.8
342.37 2751 250 886.9 4.8
343.45 2646 250 705.6 4.8
344.55 2562 250 690.9 4.8
345.63 2499 250 700.7 4.8
346.71 2415 250 666.4 4.8
347.85 2331 245 676.2 4.8
348.95 2247 245 671.3 4.8
350.03 2163 240 666.4 4.8
351.09 2121 240 671.3 4.8
« Last Edit: April 11, 2012, 09:55:30 PM by Mirez »

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #2 on: April 10, 2012, 11:37:58 PM »
Code: [Select]
Group B: '010
MAF Atmos. pressure Intake air press. Throttle
TIME 850-1050 sensor -f96- 2000-2200 100%
STAMP mg/str mbar mbar %
0.74 769.3 969 1387.2 42.4
1.84 730.1 969 1734 67.5
2.98 1043.7 969 1917.6 65.9
4.08 1180.9 969 1989 65.9
5.18 1225 969 2050.2 65.9
6.28 1244.6 969 2121.6 100
7.42 1190.7 969 2111.4 100
8.52 1151.5 969 2091 100
9.6 1107.4 969 2040 100
10.68 715.4 969 1530 0
11.79 700.7 969 1315.8 0
12.92 666.4 969 1285.2 0
14.02 666.4 969 1264.8 0
15.16 671.3 969 1254.6 0
16.28 666.4 969 1234.2 0
17.38 646.8 969 1224 0
18.48 656.6 969 1203.6 0
332.79 803.6 969 1407.6 60.4
333.87 1156.4 969 1846.2 73.7
334.95 1249.5 969 2009.4 74.1
336.05 1234.8 969 2080.8 74.5
337.15 1249.5 969 2131.8 100
338.25 1244.6 969 2121.6 100
339.35 1195.6 969 2111.4 100
340.46 1171.1 969 2101.2 100
341.61 1127 969 2080.8 97.6
342.73 744.8 969 1550.4 0
343.81 690.9 969 1346.4 0
344.91 686 969 1315.8 0
345.99 686 969 1285.2 0
347.09 686 969 1264.8 0
348.24 671.3 969 1244.4 0
349.31 671.3 969 1234.2 0
350.39 676.2 969 1213.8 0
351.45 661.5 969 1193.4 0
« Last Edit: April 11, 2012, 09:55:38 PM by Mirez »

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #3 on: April 10, 2012, 11:38:45 PM »
Code: [Select]
'011
Engine speed Spec. intake press. Actual intake press. D.cycle MAP
2850-3150 2000-2150 2000-2200 40-95%
 /min mbar mbar %
1806 1652.4 1060.8 19.9
1932 2091 1540.2 27.1
2142 2182.8 1978.8 69.7
2457 2172.6 2060.4 64.1
2772 2131.8 2091 55
3087 2131.8 2070.6 51.4
3402 2111.4 2121.6 55
3717 2101.2 2101.2 55.4
3969 2101.2 2080.8 55
3780 1030.2 1978.8 42.2
2835 989.4 1377 37.9
2772 979.2 1305.6 37.9
2709 979.2 1275 37.9
2646 969 1264.8 37.9
2583 969 1244.4 37.9
2520 969 1224 37.9
2478 969 1213.8 37.9
1743 1540.2 1111.8 19.9
1806 2203.2 1570.8 47.4
2121 2223.6 1948.2 48.6
2478 2182.8 1999.2 45.4
2793 2162.4 2121.6 53.4
3087 2131.8 2121.6 55
3360 2111.4 2121.6 55.8
3612 2101.2 2111.4 56.2
3843 2101.2 2091 55.8
3654 1020 1866.6 39.8
2667 979.2 1407.6 37.9
2583 969 1336.2 37.9
2520 969 1305.6 37.9
2457 969 1275 37.9
2373 958.8 1264.8 37.9
2289 958.8 1244.4 37.9
2205 958.8 1224 37.9
2121 948.6 1213.8 37.9
« Last Edit: April 11, 2012, 09:55:46 PM by Mirez »

Offline Chrispb

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #4 on: April 11, 2012, 12:21:25 AM »
Hi Harpster
Welcome to the forum
I'm sure Mark will look at your log files and make some sense of them, are you copy and pasteing them? you need to attach the whole file saved in your excel files, then all three logs come up side by side inline with the appropriate column heading.
Don't edit out anything as 003 is an idle reading and yours is only showing 1743+RPM
The atmosperic pressure looks out of range which may be a problem.
Boost pressure looks OK
Also bit concerned with the brake light switch, some cars have two switches, some have one switch with two sets of contacts one set is linked with engine ECU
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Chrispb

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #5 on: April 11, 2012, 08:59:58 AM »
Hi
This is how the log should look
Example is from my car with faulty EGR valve.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #6 on: April 11, 2012, 10:25:32 AM »
here is file attcahed properly.

chris, do you mean i need to take reading of group 3 only at idle
thanks

Offline Chrispb

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #7 on: April 11, 2012, 10:59:33 AM »
Thats better
Right what you need to do now is repeat the road test and start the log when you start the drive, there will be periods of tick over at junctions etc but more importantly periods of full throttle at 3000 RPM
Once saved the log will be quite long but you get a better picture of whats happening
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #8 on: April 11, 2012, 04:51:20 PM »
Hi and welcome to the forum, a good 5 minute drive should yield a host of information so as Chris says get a couple of logs done (you can do multiple blocks at a time on some versions of VCDS) and post it up - I'll gladly take a look tonight for you then! :)
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #9 on: April 11, 2012, 09:06:19 PM »
thanks mirex for finding the time, i have just got out and did a log.

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #10 on: April 11, 2012, 09:39:06 PM »
567-0
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #11 on: April 11, 2012, 09:52:37 PM »
Ok, thats the first section of your log graphed so its easier for me to understand and explain.

Blue =  is obviously the RPM,
Red = Boost pressure as expected by the ECU
Yellow = Boost pressure as provided by the turbo
Purple = D-Map, this is what N75 is doing. The lower the value the more vac is being applied so we can loosely take this as the position of the VNT.

I've highlighted the two big concerns I have with your chart with black circles, the first is what looks to be a request for boost which isn't produced:

It looks like you floor it here, the d-map drops to 35% (Its lower limit) and as result the ECU expects boost to be large however the turbo fails to produce the boost. Since the D-map is requesting and the ECU is expecting then no fault code is produced. The bigger concern here is that it looks like as you back off and the D-Map is reduced then the turbo suddenly spools up (the RPM would suggest you felt the surge?) The same repeats further down, the turbo simply doesn't produce what its being asked to.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #12 on: April 11, 2012, 10:07:14 PM »
thats right, the turbo just dont kick in at low revs until i release and the press the gas pedal, there feels like a information delay or it needs a second reminder.  I also ended up getting errors codes charge pressure control - negative deviation, which put me in limp mode and opened the duty cycle to 94%.  What do you think is going on here, is it actulator issue or a dud turbo or sensor issue.

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #13 on: April 11, 2012, 10:09:26 PM »
569-0

This is later from the same series, it looks like you floor it twice quickly, the RPM picks up naturally but without any turbo assistance. When you hold the throttle down the D-Map drops low and again the turbo fails to deliver the requested boost.

You can see the last stage of this chart the ECU trips into limp mode, the turbo generates hardly any boost yet the ECU is expecting almost maximum - the variation is so massibe that the trip happens, D-Map is disabled and no further boost will occur.

Don't underestimate that brake switch though, depending on how its failed/failing the ECU will limit the performance if it thinks you are also applying the brakes.
That said its clear the ECU is asking for boost but the turbo is failing to produce, my first though here would be that the actuator is sticking. It's clear the turbo is capable of boost so should be ok, which leads back to either a faulty N75 valve, vac pipework issues or a sticking/seized actuator.

Since the turbo will eventually spool up suggests the actuator isn't moving to where it needs to be either because its stuck/sticking or because the vac isn't reaching it. Since you've had the pipework off then I would check the pipework back together properly and airtight.
« Last Edit: April 11, 2012, 10:18:04 PM by Mirez »
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #14 on: April 11, 2012, 10:31:59 PM »
the turbo is new, should not be sooted up, the actulator moves when you start the car.  i have ordered a new n75 yesderday as i might as well change it.  Is there a way i can bypass brake switch short term just to run a test.  Could the turbo exhaust gases not be spooling up the turbo as vanes may be open. is 19.9% d cycle fine while stationary.
« Last Edit: April 11, 2012, 10:34:58 PM by harpster »

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #15 on: April 11, 2012, 10:48:42 PM »
When you say "new" - brand new? Reconditioned? Second hand?

The actuator can move, that's shown on the graph - its if its moving freely or sticking during operation that needs to be checked. You should be able to move this by hand from below and feel how easily it moves (it will require some effort to move, its how smoothly it moves you are checking). If that's ok then you are almost certainly at an air leak, either with the pipework or with the valve.

Do you have one or two switches on the brake pedal? The fault can be as simple as adjusting the plunger, but they arn't expensive if you need to replace.

The exhaust gases have to pass through the turbo so they can't not spool up the turbo, if there is a restriction in the exhaust then you'll get a similar problem though as the gases need to flow in order to spool it correctly. Since its a new cat the easy test would just be to drop it and see how she revs (loudly!)

A duty cycle at idle should be 20%, so 19.9 is spot on.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #16 on: April 11, 2012, 11:04:20 PM »
Yes, brand new, the brake pedal has just the one switch, i remember changing it about 2 years ago cost about £7.00, the exhaust i did take off and cleaned the front pipe and fitted a new cat.


Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #17 on: April 12, 2012, 09:29:12 PM »
UPDATE: Resolved matter (I think)
i have been under the car today and messed with the factory set actulator, and now my symptoms have ceased, i adjusted the rod clockwise a few turns and the car is boosting at low revs and not coughing or spluttering no more, i did fit the new n75 that did not help.  i have done a new log today showing the car running, i believe the rod may require more tweaking (iwill see how it goes)

Offline Chrispb

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #18 on: April 13, 2012, 05:10:05 AM »
They don't look good to me, but Mark will confirm
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Mirez

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #19 on: April 13, 2012, 08:35:52 AM »
It's ok, its not great as the boost pressure is still lagging behind the ECU's expected value but you can adjust the actuator again to close that gap. HOWEVER, this is why I was asking where the turbo came from, second-hand and reconditioned turbos don't get calibrated but since you have a brand-new one it would have had the rod calibrated from factory by Garrett so you would only adjust this as a last resort... I would only carry on if you are SURE you have exhausted the possibility of a vacuum leak.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #20 on: April 13, 2012, 11:08:07 AM »
Hello Chrisb, Mirez
thanks again for your valuable input, i forgot to state it not a genuine garrett, but aftermarket one, i purchased it off internet not knowing at the time if it was garrett or not. May be the reason why its set incorrectly..  but will have a proper vacuum check done.
I just was  desperate to fit it at the time as i had no transport so never returned it.  Teaches me a lesson not to purchase from a good turbo company.

Atleast i can get A to B for now.
the lagging from the turbo do i need to adjust the rod about another turn you think !!

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  • Model: Galaxy Mk2 Auto
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  • First Name: Chris
  • Region: South East
  • Country: United Kingdom
Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #21 on: April 13, 2012, 11:33:31 AM »
Perhaps they should have stuck a big label on it, "Not calibrated or will require adjustment" would have saved a lot of time and messing about.
Obviously a bit of trial and error needed now, recheck block 011 at 3000RPM, 100% throttle (flat out) make sure pressures are within range specified.
2009 Kia Sedona GS In Black 2.9CRDI 183PS. 5 Speed Manual WAV.
2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

Upgraded Eberspächer booster heater  to independent heating with 7 day timer.

With VCDS lite (full version) need a code clearing or want to scan for faults in the north kent area, PM me.
All for a pint of Strongbow.

The FordMPV.com Forum - The free forum for questions and answers relating to the Ford Galaxy, S-Max and C-Max

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3594
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #22 on: April 13, 2012, 01:59:54 PM »
Ahhh its an OE unit, hey ho you live and learn :)

As Chris says, you want to log again but in 3rd gear from 1000rpm's up to around 5000. It must be sustained full throttle through the range - post it up and I'll convert it to a graph again and you can see where you are and where you need to be :)
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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  • Spec: 03 tdi 115bhp auy
Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #23 on: April 16, 2012, 07:51:28 PM »
hi all sorry for the delay with new readings, been at close family wedding all weekend, just recovered from my 2 day hangover  ;D

i have been able to take the reading this evening it 3rd gear at full throttle, tell me what you think...

Offline Mirez

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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
  • Country: United Kingdom
Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #24 on: April 16, 2012, 09:14:41 PM »
575-0

I've removed the RPM and Cycle as they aren't so relevant now. Your graph's not at all bad but still not perfect. Its taking a little too long to reach full boost (indicated by the the sloping yellow colour when boost is requested) which would indicate that you have one or more leaks within the pipework, although nothing major as it is reaching boost. Check the inter cooler where the plastic joins the aluminium for leaks (oil vapour residue is normally evident when leaking here) and also the union at the top of the boost pipe where is does a 90* angle into the EGR/intake manifold
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

Offline harpster

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  • Spec: 03 tdi 115bhp auy
Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #25 on: April 16, 2012, 09:46:52 PM »
i did double check on the egr section and the rubber pipes at both sides of the intercooler, but could not find a leak, unless it is doing it under load, so a boost check at the garage is going have to be done, so Mirez do you think the rod is adjusted fine now or should i try it another half a turn before i take it for leak test.
thanks

Offline Mirez

  • Pondering the next mod...
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  • Posts: 3594
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  • Model: Galaxy Mk2
  • Spec: 03 115PS Ghia
  • First Name: Mark
  • Region: South West
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Re: stumbling, erratic idle, low power, revs limited 2000rpm
« Reply #26 on: April 16, 2012, 10:15:24 PM »
Not the pipes on the intercooler, when you look at it you'll see the pipes go into a plastic section. This section is clamped to the aluminium of the intercooler and its here that the leak normally occurs. There is a seal you can replace (if you can find a source) although I normally use automotive silicone.
03 Ford Galaxy 1.9 TDI 115 Ghia in Spruce Green Metallic
With cream leather interior, Full Bodykit, Remapped at 145bhp, Lowered on 18's
06 VW EOS 2.0 T-FSI 210 Sport in Deep Black Pearl
With red leather interior with full Caractere bodykit, Remapped at 255bhp and sitting on 19's
14 VW Tiguan 2.0 TDI 177 R-Line in Deep Black Pearl
With black leather interior, panoramic sunroof and bi-xenon headlights.
08 Ford Transit 2.2 TDI 115 in Frozen White
With retrofitted everything except another slidey door! :)

VCDS HEX/CAN - Scans/Coding done in Wiltshire in exchange for winegums! :)

 

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