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  #1  
Old 13th January 2013
andcro andcro is offline
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Default Engine Check Light & high idle speed after replacing turbo

Help!

I've just spent the last few days stripping and cleaning after my turbo died. The car is a 2002, 2.3lpt auto.

I have fitted a new turbo, done the new breather kit and replaced all the perished 4mm hoses, new plugs; filters; oil & coolant of course.

The car started perfectly, no smoke - so must have managed to clean out all the old oil! Once I confirmed there were no leaks and air locks - I took the car for a spin - gently to start with, no odd noises - good oil pressure - everything looks good.

After a mile or so I accelerated to check the turbo was "performing" - it certainly did, but I noted the turbo gauge went in to the red and that worried me, then the engine check and TCS light's came on, I pulled up and the idle speed had increased to 3000+rpm so I shut it off.

I checked under the bonnet - nothing obviously wrong, so I restarted the car and got it home.

I can't see anything wrong - I've checked all the connections and it all looks fine.

The only thing I worry might be wrong are the two exhaust sensors connectors - what if I got them the wrong way around? But I'm sure they are right...

I'm going to check if it is in limp home mode in the morning - and I guess this could be a one off - but has anybody else seen this before?

Thanks

Andy
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  #2  
Old 14th January 2013
andcro andcro is offline
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Default some progress - but looks like a boost problem...

I've managed to reset the limp home mode, also to clear the engine check and TCS lights.

I've driven the car again and the problem seems to be boost related - the boost gauge rises very quickly heading straight in to the red if not careful.

I've check the exhaust sensor wires - turns out they are keyed to you can't mix them up.

All pipes are fitted securely - no obvious air leaks...

I'm starting to think the turbo may be faulty?
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  #3  
Old 14th January 2013
helmetvonthrob helmetvonthrob is offline
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Default

Quote:
Originally Posted by andcro View Post
I've managed to reset the limp home mode, also to clear the engine check and TCS lights.

I've driven the car again and the problem seems to be boost related - the boost gauge rises very quickly heading straight in to the red if not careful.

I've check the exhaust sensor wires - turns out they are keyed to you can't mix them up.

All pipes are fitted securely - no obvious air leaks...

I'm starting to think the turbo may be faulty?
I doubt the turbo will be at fault, it sounds like a straight over boosting so the management is going into protection mode (limp home).

Is the wastegate connected and does the actuator work?

Check all the 4mm pipe again and make sure there are no leaks/pipes disconnected
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Old 14th January 2013
andcro andcro is offline
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Default

The waste gate is connected and I've swapped over the actuator from the old unit to see if that helped - which means I've probably just invalidated my warranty...

Not sure how to check if it is working though so if you have any suggestions?

I have checked all connections, electrical and pipe wise - going to give it another good look over later.

Its a mystery - it has to be something simple...
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  #5  
Old 14th January 2013
N.E. Swede N.E. Swede is online now
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bad BPC? I've had plenty pop right apart. Did you get the error code (DTC) before erasing?
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Old 14th January 2013
andcro andcro is offline
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Things have gone from bad to worse.....

The car starts, idles and then runs very lumpy - with the boost gauge going right over in to the red. If I add some throttle it settles down but not for long. It is now completely undriveable....

I did pull a P1300 fault code, but thats just shows a misfire....

OMG - what next...
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Old 14th January 2013
gbest gbest is offline
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Silly question, is the intake pipe still firmly connected to the throttle body?
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  #8  
Old 21st January 2013
andcro andcro is offline
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Thumbs up She's fixed!

Well - I finally got it sorted.

I drew out the whole system on paper and worked my way through it end to end. It possibly a culmination of things but the main culprit was the pipe at the end of the intercooler, it had come off just enough that I couldn't see it - but when I grabbed it to check it was firmly on I could pull it right away! I did remove and clean the MAFF as well so that may have helped.

Thanks for all the suggestions guys - I just didn't realise how much a small leak could affect how the car runs.
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