lang24 Posted January 2, 2011 Report Share Posted January 2, 2011 Hey guys complete newbie on this site, am hoping somone can help me out. i have a 2002 bora tdi sport 150pd currently on 86k couple of weeks ago was changing motoways and decided to give it beans up the sliproad to join the motorway changing from 2nd to 3rd the car went into limp mode and could only achieve 2000rpm 60mph! after stopping and restarting the car everything was fine and car had power back. 2 weeks later and i had to make a 300mile round trip to my aunties involving mostly motorways and some country roads, the journey up was fine with the occasional vibration lasting a second under load at about 60mph, got to my aunties and the car stood for 5hours ish. went to drive back started fine but ran lumpy on idle, when throttle applied car shakes violently and a "flapping/popping" sound can be heard:eek:! i stopped at the petrol station opened the bonnet and could hear the exhaust backing up the air intake! power is limited to 60 unless you fancy being shaken to pieces, i know all the turbo hoses are on because i recently had to replace one, so checked the rest at the same time. i suspected a blocked exhaust so separated the exhaust from the turbo and ran the engine, still the same but this time filling the engine bay with blueish/grey smoke. the car has full service history (the last two carried out by myself on the driveway) next service is flashing up in 400mile, hope someone can shed me some light as to where and what to go/do. many thanks guys. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted January 2, 2011 Report Share Posted January 2, 2011 Hi there......one of 2 things, turbo has completely given up ie the shaft has snapped in 2 and yes they do run at times or on those early ones 150bhp pd's the camshafts do wear giving you all sort lumpy running, lack of power but at times poor or non start. Which both are costly jobs. Best thing to do judging you seem to be of mechanical mind take exhaust off again.....bugger i know and the opposite side the inlet compressor side and inspect. Grab both sides see if you have any damage to turbine blades,free to turn no excessive play back and forth as well as up and down. Failing that cam cover off and inspect the camshaft and the hydraulic lifters too....thats the easy one to find. Any probs PM me best regards Tidy Link to comment Share on other sites More sharing options...
lang24 Posted January 4, 2011 Author Report Share Posted January 4, 2011 Thankyou for your advice tidy, took the exhaust back off! (easier this time round) and the intake and check the blades on the turbo, they were fine tiny bit of movement but not massive amounts. i then focused on ripping the rocker cover off to check the camshaft and found it wasnt healthy. so im thinking that is my problem. have taken it to a mates garage for him to do a compression check and second opinion. will update when i know more but again thanks for the advice. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted January 4, 2011 Report Share Posted January 4, 2011 Comp test wont show much really. But trust me if your cam aint healthy you need to replace that, the lifters(hydraulic tappets) the bearing shells cant honestly remember how many there are, cam seal, tandem pump gasket and the bearing cap bolts, roller rocker bolts and the cam sprocket bolts too.......let me know how you get on. Regards Tidy. Link to comment Share on other sites More sharing options...
lang24 Posted March 2, 2011 Author Report Share Posted March 2, 2011 Heya guys sorry ive been so quiet lol, been busy fixing the bora! turns out was the camshaft at fault. So replaced all the parts tidy listed, took me a while due to only having time to work on it at the weekends but sure enough got it done and no runs really smooth but there is a further problem which is really baffling me. upon acceleration from idle to around 2700rpm there is no turbo assistance watsoever (cant even hear the satisfying hiss) when it eventually gets to 2700rpm it feels like the turbo boosts until 3500-4000rpm. i initially thort id left a vacuum pipe undone but ive checked it more than twice and everything i took off i put back. but still this niggle is here hoping maybe u guys have some ideas. any advice would be gratefull. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted March 2, 2011 Report Share Posted March 2, 2011 GOOD WORK!!!!!!!!!!!! Nice one my friend satisfying i bet? Right sounds like couple of things really....... check all you vac pipes for splits and i mean all of them....any doubt kick em out and replace them. Check the actuator for the turbo where it hinges at the variable vanes....use a vacuum tester it should be free all the way. Last but not least get a genuine Air Mass meter which it more than likely is on this it should sort you out or get a known good donor one and try it.......best regards Lang, Tidy Link to comment Share on other sites More sharing options...
lang24 Posted March 2, 2011 Author Report Share Posted March 2, 2011 Tidy thankyou so much for the rapid response, you are fast becoming a mate of mine lol. i have had all the vacuum hoses off the car last weekend when i noticed the problem and none of them are split, my first thort was a vacuum leak or that id been clumsy and left one off. But with this bora nothing seems to be that easy lol When you say check the actuator do you mean attach a vacuum pump onto the turbo? or the vacuum pipe itself? and im guessing if the actuator doesnt move freely its a new turbo? As for the air mass meter ive never put one on it in the time ive owned it (roughly two years) but i can source one from a mate who works for vw so should be genuine enough Im hoping its an air mass and not a turbo mainly due to them being roughyl 500quid on top of about 400 already spent on the camshaft and parts. tis a shame because its been a joy to own upto now. I sahll try your suggestions though and report back, once again thankyou for your time and advice mate im extremely grateful. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted March 2, 2011 Report Share Posted March 2, 2011 No worries mate at all! Vacuum pump on the turbo actuator and check it. Does sound like an Air mass though. Good luck. Link to comment Share on other sites More sharing options...
lang24 Posted March 3, 2011 Author Report Share Posted March 3, 2011 Quick update tidy, ive been out tonight vacuum checking the turbo, the rod moves freely. am gonna purchase an air mass from my mate at vw hopefully tomorrow and give that a try. Fingers crossed. Link to comment Share on other sites More sharing options...
lang24 Posted March 5, 2011 Author Report Share Posted March 5, 2011 Tried a brand new vw air mass meter this morning and no joy still the same, its drives like a 110! starting to give me a headache lol. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted March 7, 2011 Report Share Posted March 7, 2011 Ok well it was good to try, as with these they do throw a curve ball like that. Either a N75 charge pressure control valve hoping you put the pipes on the way they came off, or possibly a map sensor. I believe its on one of the pipes front of the engine on a 150 as they have a front mounted intercooler. Vagcom checking measure blocks would tell you what the pressure readings are with ignition on......it will stick out like a sore thumb. MVB 10 or 11 i think. Link to comment Share on other sites More sharing options...
lang24 Posted May 8, 2011 Author Report Share Posted May 8, 2011 Hey Guys Sorry its been a while, been kinda busy changing jobs and so on. The bora is in pieces and im gonna send the turbo away to be reconditioned (a mate at work did this to his Galaxy tdi and its fixed) i tried everything i could with this car, various sensors, vacuum checks even 2 diesel specialists have had it. 1 tells me he cant work out what the problem is and 2 reckons they tested it against another 150 golf and they exactly the same?????? i get it back and clearly its not but the other night it completey lost it and went into limp mode so i stuck my obd tester on it P1557 Charge pressure control comes up. So my view is the turbo must be at fault so after a few hours and f**ks later the turbos in a box and im sending it away tomorrow. hoping this helps then contemplating selling it as its jus one thing after another. Link to comment Share on other sites More sharing options...
lang24 Posted May 22, 2011 Author Report Share Posted May 22, 2011 Just a quick update for those who having similar problems, sent the turbo to www.turborepairs.com located in blackpool they send a courier out to collect ur broken turbo strip it right down clean it replace bearings and seals put it back together test it and balnce it up then give it a lick of heat resistant paint plus a years garuntee all for £300!! it returned 3 days later fitting it back on the car and FULL power is BACK!!!! fallen back in love with the car. and hopefully no more problems. many thanks to tidy who has been a well of knowledge to me. this is by no means the last of me lol. Link to comment Share on other sites More sharing options...
TIDYDUBS Posted May 22, 2011 Report Share Posted May 22, 2011 No worries there at all my friend, glad to be of service!!!!! Link to comment Share on other sites More sharing options...
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