'HDi's for Dummies' diagrams?

[old'uns]

so the next installment....
out this morning, stripped off the gubbins again and found an open ended fitting on the vac reservoir

pipe connected to it and tee'd in to the pipe from the vac pump and to the solenoid on AC, seemed the most logical way the way the plastic pipes sat?

out for test, still the same , flat as....no boost
this was on the faults log from drive


actuator tests...
fuel flow reg...OK
fuel press reg...OK
EGR valve ...clicks
EGR electrovalve...not at first but faintly when pipes to Vac res were swapped, low vac pressure?
inlet air heater throttle electro...OK
Turbo pressure...not at first, again better when vac res pipes swapped

live data screenshots, stationary...excuse the quality, phone got a bit grubby





off out to lunch later and then a sit down in a dark room and a sob in the corner

i'm reluctant to take off EGR at moment, no time and may not achieve anything

[GiveMeABreak]

Here's the data on those codes:

Engine ECU SIEMENS SID803

P0102

Fault Code	P0102
After Sales Description of the Fault Code	Flowmeter Signal: Measured Flow Less Than the Minimum Flow
Description of the Diagnostics	The Signal issued From the Sensor is Outside the Electrical Tolerance (Frequency too High)
Conditions of Activation of the Diagnostics	Battery Voltage More Than 7,45 V
Conditions of Disappearance of the Fault	Ignition On
Down-Grade Modes If Fault Present	The Engine ECU No Longer Regulates the EGR Valve
Switching On of the Warning Lamp and /or Warning Message	Warning Lamp MIL
Main Customer Complaints Likely	Lack of Power
Suspect Areas	Air Flow Meter Electrical Harness

P2562

Fault Code	P2562
After Sales Description of the Fault Code	Turbo Position Copy Signal Fault: Positive Gap Between the Reference Turbo Position And the Position Measured
Description of the Diagnostics	the Fault is Forwarded If the Difference Between the Reference Value is Above 30% at the Actual Position (For at Least 8 Seconds)
Conditions of Activation of the Diagnostics	Engine Speed Above 1500 RPM Engine Torque Higher Than 120Nm
Conditions of Disappearance of the Fault	Driving For 5 Minutes
Down-Grade Modes If Fault Present	Inhibition of the Flowmeter Plausibility Faults Torque Limitation For Traction Control Deactivation of Forced Regeneration of the Particle Filter By the Diagnostic Tool Switching On of the Warning Lamp And/Or Warning Message
Main Customer Complaints Likely	Lack of Power Noise Smoke From the Exhaust
Suspect Areas	Turbocharger Position Copy Sensor Electrical Harness Connector Vacuum Problem The Variable Geometry of the Turbocharger is Locked Particle Filter Air Metering Valve

P0299

Fault Code	P0299
After Sales Description of the Fault Code	Turbocharger Pressure Signal: Pressure Too Low In Relation To the Reference Value
Description of the Diagnostics	Difference Negative For 10 Seconds, Between the Turbo Pressure Reference and the Measured Turbo Pressure: the Turbocharger Pressure is Below 800 Mbars at the Reference Point, For An External Temperature of 20 °C And at An Altitude of 0 M
Conditions of Activation of the Diagnostics	Engine Speed Above 1000 RPM The Actual Engine Torque is Higher Than 70 Nm
Conditions of Disappearance of the Fault	Driving For 5 Minutes
Down-Grade Modes If Fault Present	Downgrade ASR Mode (Torque Limitation For Traction Control) Deactivation of the ASR (Wheel Anti-Skid ) Deactivation Speed Limiter Until the Next Time the Ignition is Switched On Deactivation of the Speed Limiter Deactivation of the Cruise Control Deactivation Cruise Control Until the Next Time the Ignition is Switched On Closing of the EGR (Exhaust Gas Recycling) Valve Switching On of the Warning Lamp and / or Warning Message
Main Customer Complaints Likely	Lack of Power Noise Smoke From the Exhaust
Suspect Areas	Air Meter Restricted Clogged Air Filter Obstacle Obstructing the Air Passage Air Lock Between Compressor And Engine Turbocharging Pressure Sensor Turbocharger Position Copy Sensor Vacuum Problem Turbocharger

[EDC5]

I think your car would benefit from an overhaul of the vacuum actuation system.

I'm sure getting hold of thin bore rigid pipe wouldn't be too hard and then you could replace all of the questionable tube.

[old'uns]

thanks all so far....

so could still be anything at moment although most likely EGR / Turbo press sensor or vacuum
any easy checks to check for vac pressure/pump?
EGR needs cleaning that's probably a given but not able to do immediately.
P0299 code doesn't affect the Cruise, that still works surprisingly, the X7 before was very fickle on that
would benefit from a new temp sensor in inlet/doser maybe?
turbo copy position / pressure sensor as well

i'm slowly getting to the tipping point of money vs common sense

[EDC5]

I think the pressure sensor in your inlet manifold would benefit from being changed myself. It's probably full of that carbon gunk, possibly clogging the diaphragm.

Also, you may need a new MAF (that includes a temp sensor) as the inlet temp of -49 wont be helping things.

The main issue seems to be the vacuum system that actuates the turbo, if there are no vac leaks then I'd suspect the solenoid valve.

[old'uns]

the temp sensor i cleaned with cleaner as per a MAF
the MAF is new, i may try the old one again just in case
the pressure sensor i'm assuming is the one that is a small short stub with a hole in it next to the Temp one?
i've tried to eyeball the vac pipes as much as possible, nothing obvious stands out

[EDC5]

That's odd, there must be another reason for the erroneous freezing cold temp reading then.

Yes, that's the one, its short stub sticks into the doser housing so it can sense the pressure. Is it blocked up perhaps?

If the piping is all ok, then there may be a physical reason why the vanes on the turbo won't move. I'd be tempted to try this 'easier' step first:

[old'uns]

the reality is at the moment it was bought as a cheap runaround

so as it stands it has little value to anyone else and i dont particularly want to PX and spend an half decent amount out, so in for a penny....

MAP sensor and Intake temperature sensor ordered for collection Tuesday, ECP £48 with their currrent discount, eBay etc was at least £55+ and no guarantee of delivery dates, at least on Tue evening i can simply unplug / unscrew and try.
i'll look at that video later, if time on Tue i'll try that as well.

IF i get to Turbo replacement territory i may regret the 2nd sentence

[MikeT]

I don't think there's anything wrong with the MAF.
Cleaning the doser press sensors is worth doing.
Check the turbo is getting proper vacuum (if you haven't done so). If you can reach the turbo actuator rod, push it in and release, it should return under firm spring pressure. Have someone start the engine and you should see it get pulled into the diaphragm by about 12mm.

[Simple76]

If you rev the vehicle when stationary does the rubber turbo pipe from inter cooler expand . If so turbo working . Simple test to try. I would be taking EGR valve off and checking. Egr valve will cause many of the faults listed. They are not as difficult to change as appears.

[old'uns]

x fingers i can get something done tomorrow evening, plenty to go at thanks all.
strangely enough today and tomorrow, working at a well known engine specialists in Northampton, some blokes called Costin and Duckworth started it 60 yrs ago although i fear even they may not be able to help me, too low tech i think

[MikeT]

You can test the whole vacuum system with a low-tech vacuum kit.

[Paul-R]

... some blokes called Costin and Duckworth started it 60 yrs ago although ...

Sadly no longer with us unless you can communicate by Ouija board.

A couple of great engineers. Thanks for the reminder.

[old'uns]

Mike Costin is still about, sure someone mentioned he was 89?, apparently going in on Thursday for a look around and to sign the frosted door panels that bear his name

[Paul-R]

Quite right. My addled brain was thinking of his brother Frank Costin (the cos in Marcos). Apologies.