Multiple faults regarding boost pressure

[Davi926]

Evening and new year to you all.
Having issues with my 1.6tdi caddy 2011 (cayd)
Bought a few months back and been waiting to get vcds so i could show my results on here.

Address 01: Engine (J623-CAYD) Labels:. 03L-906-023-CAY.clb
Part No SW: 03L 906 023 PC HW: 03L 907 425 C
Component: 1,6l R4 CR td H43 4991
Revision: --H43--- Serial number: 00000000000000 CVN: 0235DCA1
Coding: 00114010030500080000
Shop #: WSC 35110 790 50316
ASAM Dataset: EV_ECM16TDI02103L906023PC 003007
ROD: EV_ECM16TDI02103L906023B_003.rod
VCID: 76E353DFC9C73423E1-8022
VINID: 9E606AAAA09BA95A000451C51CDDEF3687

5 Faults Found:
7295 - Manifold Pressure / Boost Sensor (G31)
P0238 00 [032] - Signal too High
Intermittent - Not Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 2
Mileage: 283131 km
Date: 2023.10.20
Time: 16:11:56

Engine RPM: 2186.00 /min
Normed load value: 85.9 %
Vehicle speed: 34 km/h
Coolant temperature: 21 °C
Intake air temperature: 18 °C
Ambient air pressure: 960 mbar
Voltage terminal 30: 14.456 V
Unlearning counter according OBD: 20
Engine RPM: 2202 /min
Vehicle speed: 52 km/h
Accelerator position: normalized-Accelerator position: 65.23 %
Charge air pressure: specified value-MAP_SP_MMV: 2465.88 hPa
Charge air pressure: actual value-MAP_MMV: 3000.04 hPa
Charge Pressure Actuator: activation-ANG_SP_BPA[0]: 15.051 %
Charge air pressure actuator: acknowledgment-ANG_BPA[0]: 17.737 %

7286 - Turbocharger Boost Control Position Sensor Circuit
P2563 00 [237] - Implausible Signal
MIL ON - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 1
Mileage: 283099 km
Date: 2023.10.15
Time: 14:39:35

Engine RPM: 972.75 /min
Normed load value: 29.4 %
Vehicle speed: 0 km/h
Coolant temperature: 53 °C
Intake air temperature: 20 °C
Ambient air pressure: 1020 mbar
Voltage terminal 30: 14.344 V
Unlearning counter according OBD: 40
Charge air pressure actuator: acknowledgment-ANG_BPA[0]: 16.644 %
Charge Pressure Actuator: activation-ANG_SP_BPA[0]: 85.001 %
High press turbocharger actuator: activation-CTL_LIM_BPA[0]: 84.998 %
High press turbocharger actuator: actual uncond volt value-V_BPA[0]: 0.679 V
Turbocharger boost control: offset open-V_BPA_BOL[0]: 0.498 V
Turbocharger boost control: offset closed-V_BPA_TOL[0]: 3.120 V
High press turbocharger actuator: status-LF_STATE_BPA_DISP[0]: 12

7384 - Boost Pressure Regulation
P0299 00 [104] - Control Range Not Reached
Intermittent - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 4
Mileage: 283241 km
Date: 2023.10.23
Time: 13:25:02

Engine RPM: 2265.25 /min
Normed load value: 63.9 %
Vehicle speed: 75 km/h
Coolant temperature: 107 °C
Intake air temperature: 21 °C
Ambient air pressure: 980 mbar
Voltage terminal 30: 14.231 V
Unlearning counter according OBD: 38
Charge air pressure: specified value-MAP_SP_MMV: 2465.30 hPa
Charge air pressure: actual value-MAP_MMV: 1244.34 hPa
Air mass: actual value (mg/stroke)-MAF_MES: 540.297 mg/stroke
EGR Solen.val.: actual value-ANG_EGRV[0]: 0.000 %
Throttle valve adapter: actual value-ANG_THR[0]: 95.868 %
Charge air pressure actuator: acknowledgment-ANG_BPA[0]: 92.926 %
Engine torque-TQI_SP: 193.03 Nm

6141 - Coolant Fan Control Circuit 1
P0480 00 [044] - Electrical Malfunction
Intermittent - Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 10
Mileage: 283258 km
Date: 2023.10.23
Time: 13:55:20

Engine RPM: 1315.50 /min
Normed load value: 56.9 %
Vehicle speed: 44 km/h
Coolant temperature: 102 °C
Intake air temperature: 20 °C
Ambient air pressure: 980 mbar
Voltage terminal 30: 14.231 V
Unlearning counter according OBD: 40
Engine RPM: 1792 /min
Vehicle speed: 15 km/h
Sensor for temp after charge air cooler: raw value-TBA_MES: 11 °C
Sensor for engine block temperature: raw value-Coolant temperature: 102 °C
Outside temperature-Ambient temperature: 6.75 °C
Coolant fan 1: activation-Radiator fan 1: activation: 55.5 %

6146 - Radiator Fan (V7)
P1950 00 [109] - Movement Restricted / Jammed
Confirmed - Tested Since Memory Clear
Freeze Frame:
Fault Status: 00000001
Fault Priority: 2
Fault Frequency: 73
Mileage: 283103 km
Date: 2023.10.16
Time: 08:00:20

Engine RPM: 981.75 /min
Normed load value: 19.6 %
Vehicle speed: 0 km/h
Coolant temperature: 58 °C
Intake air temperature: 8 °C
Ambient air pressure: 1010 mbar
Voltage terminal 30: 14.344 V
Unlearning counter according OBD: 40
Vehicle speed: 26 km/h
Sensor for temp after charge air cooler: raw value-TBA_MES: 11 °C
Sensor for engine block temperature: raw value-Coolant temperature: 102 °C
Coolant temperature at radiator outlet: actual value-TCO_2: 36 °C
Outside temperature-Ambient temperature: 6.75 °C
Ambient air pressure-Ambient pressure: 1004.96 hPa
Coolant fan 1: activation-Radiator fan 1: activation: 51.6 %

Readiness: 1010 0000

I don't believe the radiator fans to be an issue as they work normally but the 3 faults regarding boost are what im more concerned about. flashing glow plug light and will go into limp mode and will need to turn the engine off and on to get boost back but that only lasts from a few seconds to a few minutes before happening again.
Ive already checked the actuator and it travels freely, checked the vacuum lines with a tester and hold vacuum no issue.

What i do know is the egr and dpf has been deleted and coded out and was told it had a new engine before i purchased it so was maybe thinking it could be in relation to the engine change but could just be a coincidence as i wasn't there and got it with the faults.

Any help would be much appreciated. Thankyou

[BenT]

Has the engine definitely got the correct turbo on it for that engine? It almost sounds as though the ECU's telling the turbo what to do and it's getting more than it bargained for... Unless it's had a dodgy remap.

[PeterAFox]

if you now have vcds, it's often helpful to plot the expected and actual air flow (maybe post the graph?)
you actually get a fault for your G31 (Manifold Pressure / Boost Sensor), so maybe worth checking first - could be wiring or the sensor.

there's a test in vcds (basic test..?) to check the operation of the turbo actuator (you can watch it with the engine running) - you could take off hose to actuator and use a vacuum gauge to measure the vacuum while the test is running.
If vacuum good, then maybe turbo. ...?
If your vacuum is not good but hoses are good, then possibly air filter, N75, a non-return valve or vacuum pump.
Sometimes hose leaks are not easy to find (I recently acquired a smoke tester, which has proved very useful for such things). Also, I read somewhere that a faulty EGR changeover valve (N345) can affect the vacuum in N75 valve.
There's a useful diagram on p.271 of the vw/erwin workshop manual for your engine (D3E802E92D9-4-cylinder_diesel_engine_(1_6_l_engine__common_rail).pdf) - maybe also in the haynes manual.
It's worth paying for erwin for an hour and downloading all the docs you can in the time (when I did it, it was only 7€ plus VAT. start with your own vehicle of course)

[Davi926]

Thanks for the replies. Id say yes it certainly was remapped before purchase as the DPf and egr were mapped out. Would make sense it was mapped for more power at the same time
I have spoken to the previous owner and although gaining ignorance (suspected he would) he did say he changed the map sensor.
Back when I had my MK1 Fabia I know that I needed to put in a higher bar map sensor in when I modded it. Not sure if it could be the same situation here but obviously that would throw one fault code not 3. I'll check it out and run the test and get back to you.

[Davi926]

Ok so ran the actuator test 3 times and it passed everytime and acuator moved. the turbo is 03l2530560v500 which seems to be the one on thats for the cayd engine.
Map sensor part number is 093320882 cant seem to track what bar this sensor is though.
ive uploaded the the log of a few pulls to my google drive - https://drive.google.com/file/d/1kd0f9R ... drive_link

left is requested boost and right is actual. did pulls in 2nd, 3rd and 4th. funny enough when doing pulls it was fine and the log shows that the boost requested is achieved, however with the engine running and idling whilst i was looking for the test of the actuator it went into limp mode several times always seems to be when it cruising or light to mid throttle not so much when flooring it like in the logs ( although I never drive with a lead foot so wouldnt know)

every time it did go into limp mode in idle it was the P2563 00 [237] - Implausible Signal fault code that was popping up.
Last time i used vcds it was 11.11 so everything is called different in the logs so go easy if i messed something important

[Davi926]

Was looking on a different site about it could be the turbo coked up. If that's the case would it need to be replaced or could I remove it and clean it?

[PeterAFox]

Your graphs are not openly accessible ;-)
Fault code: P2563 - my docs say:

Wiring/Connector(s).
Fuse(s).
Turbocharger (TC) boost control position sensor (G581) faulty.
Engine Control Module (ECM).

Possible Solutions:
Check/Replace Wiring/Connector(s).
Check/Replace Fuse(s).
Ohm test Turbocharger (TC) boost control position sensor (G581), see factory repair manual.

Personally, I wouldn't think about changing the turbo yet - in my experience, 'implausible signal' faults normally turn out to be damaged wring or faulty sensors. I think the G581 is the sensor on top of your turbo actuator - do a search for what the resistances should be. If it's the sensor or wiring, it would be much cheaper and easier to fix than changing the whole turbo. Oh, and of course, check the fuse first :-)

[Davi926]

Hi I updated the file so you can view. That was my bad

[PeterAFox]

Ok, a table is almost a graph, but not quite.

The specified and actual charge air pressure values seem to be more or less in line, but not so easy to tell from a quick look at the table.
The IDE00396 seems weird to me. I don't know where (which sensor) this is generated from.
Which MVB is it?
Did you test the G581?
You could try searching ross-tech properly, and as you have a VCDS, try posting there.
If you get more info, please post back here....
If I have time later, I'll have a closer look