New turbo/ underboost/cruise control

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Benscab123
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New turbo/ underboost/cruise control

Post by Benscab123 »

Just fitted a new turbo but it seems whenever I use cruise control I get a turbo underboost fault P0299. Any ideas anyone please ? I do have a recurring EGR insufficient flow fault if that could be anything to do with it.
Thanks.
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

Fault 2099:

Description: Turbocharger pressure signal - Pressure too low in relation to the reference value. Difference negative for 5 seconds, between the turbo pressure reference and the measured turbo pressure. The pressure measured is lower than the reference, around 300 mbars for an engine speed above 2500 rpm.

Fault will be triggered:
  • In particle filter regeneration with engine speed above 1800 rpm
  • Not in particle filter regeneration with engine speed under 1500 rpm
Conditons for fault disappearing: Driving for 5 min with several full load accelerations for 10 seconds.

Downgrade Modes Activated Whilst Fault Present:
  • Use of the flow calculated
  • Cutting of the EGR butterfly (turbo air cooler), EGR valve and bypass butterfly (inlet air heater) in all operating modes
  • Cutting of cruise control
  • Change to "easy move" torque invalid (Deactivation of automatic mode for the electronic parking brake)
Symptoms:
  • 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
  • Variable geometry of the turbocharger jammed in the "minimum turbo" position
  • Faulty turbocharger
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Re: New turbo/ underboost/cruise control

Post by admiral51 »

Assuming this is the 1.6 Hdi in your profile and just guessing that it has the same engine as my old C5 X7
Have a look at Devil Car
Turbo solenoid valve, cheap as chips but depending on location within the 1.6 engine bay is a mare to get to but caused me no end of aggro but worth a look at
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Re: New turbo/ underboost/cruise control

Post by Benscab123 »

GiveMeABreak wrote: 14 Nov 2019, 15:31 Fault 2099:

Description: Turbocharger pressure signal - Pressure too low in relation to the reference value. Difference negative for 5 seconds, between the turbo pressure reference and the measured turbo pressure. The pressure measured is lower than the reference, around 300 mbars for an engine speed above 2500 rpm.

Fault will be triggered:
  • In particle filter regeneration with engine speed above 1800 rpm
  • Not in particle filter regeneration with engine speed under 1500 rpm
Conditons for fault disappearing: Driving for 5 min with several full load accelerations for 10 seconds.

Downgrade Modes Activated Whilst Fault Present:
  • Use of the flow calculated
  • Cutting of the EGR butterfly (turbo air cooler), EGR valve and bypass butterfly (inlet air heater) in all operating modes
  • Cutting of cruise control
  • Change to "easy move" torque invalid (Deactivation of automatic mode for the electronic parking brake)
Symptoms:
  • 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
  • Variable geometry of the turbocharger jammed in the "minimum turbo" position
  • Faulty turbocharger
Thanks Marc, I have noticed when fitting the new turbo that there doesn’t seem to be as much clearance between the new oil feed pipe and the actuator rod as there was on the original turbo. I bought a replacement pipe to go with the new turbo.
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

Have you got the correct procedure for removing / fitting? It's a bit involved and there is a specific procedure you need to follow after connecting everything up before starting the engine? If you want me to post it up let me know . There may be something in there that you haven't followed...

Plus - did you fit the new banjo bolt with the revised filter / strainer? This was also a modification as the old type can clog and starve the turbo of oil.
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Re: New turbo/ underboost/cruise control

Post by Benscab123 »

Was fitted by a mechanic friend so I assume it was done correctly , however I did notice that he didn’t use one of the very small paper gaskets supplied with the turbo (not sure what it was for). I’ve alsi just noticed that there is a small oil leak (leaking at or onto the top of the actuator). No didn’t fit new banjo but old one was thoroughly cleaned out .
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

I have a bit of time, so will put it up anyway:

Removing / Refitting Turbocharger - C4 Picasso 1.6 HDi 110 FAP (DV6TED4)

Removing
  • Disconnect the battery.
  • Remove the engine style cover.
Cautions:
  • Protect the engine cooling radiator to prevent damage to the fins.
  • Plug the turbocharger inlet and outlet openings.
Remove the catalytic converter and particle filter assembly

Remove:
  • The air inlet sleeve from the turbocompressor
  • The turbocharger noise attenuator
Note: Remove the turbocharger noise attenuator pivoting it in the centreline of the turbocharger manifold.
Benscab A.PNG
Benscab B.PNG
Remove:
  • The bolts (1)
  • The heat shield (2)
  • Uncouple the vacuum pipe (3) ( as "a").
Note: Keep the filling cylinder full.
Uncouple the lubrication return pipe (5) ( as "b").

Note: When slackening the unions, ensure that they do not rotate (Support them if necessary)

Remove the lubrication pipe (6), allen screws (4) and ring seals assembly.
Benscab C.PNG
Benscab D.PNG
Note: Check there is no strainer present at "c" on the bolt (4b). Remove (If necessary) by means of a screwdriver.Remove:
  • The (7) bolt
  • The nuts (8)
Benscab E.PNG
Remove:
  • The nuts (10)
  • The turbocharger (9)
CAUTION: Protect the exhaust manifold using the closer.
Checks:

Examine the engine air filtering system.
Check:
  • The air hoses
  • The condition and the correct positioning of the turbocharger vacuum pipe.
Check the absence of foreign bodies in the following components:
  • Induction circuit
  • Exhaust gas manifold (it may cause the destruction of the turbocharger when operating it)
Clean the surface of the turbocharger exhaust manifold .
Check that the oil circuit unions are clean.

Note: Use the recommended bolts and nuts (heat resistant).

Replace:
  • The turbocharger mounting nuts
  • The turbocharger lubrication banjo bolt copper seals
  • The catalytic converter clips
Refitting

Cautions:
  • At refitting, all the removed seals must be replaced with new seals.
  • When refitting : Remove the blanking pieces on the turbocharger at the last moment.

Benscab F.PNG
Replace the seals "d" and "e" of the turbocharger.

Benscab G.PNG
Cautions:
Clean the gasket faces with an approved descaling product.
Do not use abrasives or sharp tools on the joint faces.
The gasket faces must not have any traces of knocks or scores.

Pre-fit the components of the turbocharger,
in order to adjust their position (Before final tightening).

Always replace: The nuts (8), (10) and the bolt (7).

Couple the turbocharger to the exhaust manifold.

Fix:
  • The nuts (8), (10) (new nuts)
  • The (7) bolt (new)
Put the lubrication pipe (9), allen screws (7) and ring seals assembly in place (new).
Tighten:
  • The nuts (8), (10) to 2,6 ± 0,6 daN.m
  • Screw (7) to 2,5 ± 0,3 daNm
Note: On refitting, lubricate the end of the lubrication return pipe using engine oil.

Couple up:
  • The lubrication return pipe (5)
  • The vacuum pipe (3)
Benscab H.PNG
Benscab I.PNG
Method for tightening the upper union:
Put a ("A" = 8,5 mm) diameter pin in place vertically, as indicated above
Tighten the bolt (4a) supporting the union using the pin; Tighten to 3 ± 0,45 daN.m
Method for tightening the lower union:
Put a ("B" = 7,5 mm) diameter pin in place horizontally, as indicated above
Tighten the bolt (4b) supporting the union using the pin; Tighten to 3 ± 0,45 daN.m
Benscab J.PNG
"C" Incorrect fitting of the lubrication pipe.
"D" Correct fitting of the lubrication pipe .
"F" Authorised angle of movement: 3° (0; +0,2).

CAUTION: Placing the lubrication pipe under stress will result
in engine oil leaks; After tightening the unions,
check that the lubrication pipe moves freely;
Otherwise, repeat the unions tightening operation and replace the seals.


Couple up: The vacuum pipe (6) ( as "a").

CAUTION: Carry out a pre-fitting to adjust the position of the
catalytic converter and particle filter assembly.
Refit the catalytic converter and particle filter assembly.

Refit:
  • The heat shield (2)
  • The bolts (1)
  • The turbocharger noise attenuator
  • The air inlet sleeve from the turbocompressor
Benscab K.PNG
Tighten:
  • The bolt (11) to 1 ± 0,1 daN.m
  • The shoulder bolt (12) ; To 0,5 ± 0,1 daNm
Reconnect the battery.
Precautions to be taken before starting the vehicle
  • Disconnect the connector of the diesel injectors.
  • Turn the engine over with the starter motor for 15 seconds.
  • Reconnect: The diesel injector connectors.
  • Let the engine run at idle for 30 seconds before increasing the load.
  • After switching on, check the sealing of the various unions.
  • Clear the faults in the memory, using the diagnostic equipment.
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Re: New turbo/ underboost/cruise control

Post by Benscab123 »

Thanks yet again Marc, your knowledge of these beasts is amazing.
Please could you also tell me the part number for a replacement EGR valve, may aswell change that too, if only to eliminate it. Thanks.
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

Part number: 1618NR (item (1) £425.58 from Citroen inc. VAT...... are you sure you want to change it now? :-D
Benscab EGR.PNG
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Re: New turbo/ underboost/cruise control

Post by Benscab123 »

Absolutely certain....................ly not 😂😂😂😂
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Re: New turbo/ underboost/cruise control

Post by Gazzaman22 »

Hello Marc

I am to take a turbo from an old c5 to put into my current c5, I'm going to get organised and gather up a few bits and pieces needed for the operation and try to get at it maybe next month, i will remove the turbo from my old car myself and give to a proper mechanic to fit.
Can I ask you about a few things on this.
What all new parts would you recommend i need? (seals,nuts bolts and gaskets? Would you have part numbers for each or where can i order from - could i order from a Peugeot garage because there is one close to where i live?)
Last edited by GiveMeABreak on 23 Feb 2021, 09:09, edited 1 time in total.
Reason: Removed Replicated Procedure
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

Ok, so these are the recommended parts to be replaced according to the procedure. All these are actual Peugeot part numbers, so if you ring them up directly and quote the part numbers they will know what you are wanting.
gaz Turbo bits.PNG
image_2021-02-23_094701.png
Item (72) MUL Self-Locking Nut, Part 6935A5 x 4 £4.25 each
Item (7) Copper Gasket, Part 015708 x 4 £2.47 Each
Item (14) Intake O Ring Seal, Part 144081 £2.14
Gaz Seals.PNG
image_2021-02-23_093335.png
Item (14) Sleeve, Part 1434C8 £20.58Item (10) Exhaust Clamp, Part 171360 £12.88
Item (13) Exhaust Clamp, Part 171377 £14.78
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Re: New turbo/ underboost/cruise control

Post by Gazzaman22 »

One more thing, would it be advisable when I'm at it to take the dpf from old car, and get it cleaned and then put it into current car?
What's the removal procedure like?

Anybody any experience of getting DPF cleaned? Any good?
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Re: New turbo/ underboost/cruise control

Post by GiveMeABreak »

It won’t hurt to have a spare or swap them as you’ll be working around there anyway. But if you do this, remember to tell the engine ECU you have replaced the DPF under the repair menu, so it know this.
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Re: New turbo/ underboost/cruise control

Post by Gazzaman22 »

GiveMeABreak wrote: 23 Feb 2021, 09:58 Ok, so these are the recommended parts to be replaced according to the procedure. All these are actual Peugeot part numbers, so if you ring them up directly and quote the part numbers they will know what you are wanting.
ImageImage
Item (72) MUL Self-Locking Nut, Part 6935A5 x 4 £4.25 each
Item (7) Copper Gasket, Part 015708 x 4 £2.47 Each
Item (14) Intake O Ring Seal, Part 144081 £2.14
ImageImage
Item (14) Sleeve, Part 1434C8 £20.58Item (10) Exhaust Clamp, Part 171360 £12.88
Item (13) Exhaust Clamp, Part 171377 £14.78
Any chance you have a removal proceudre for the DPF please, and can the whole unit be removed in one peice rather than just taking out the insides of the unit?

EDIT------I think i see why mine wont come out now..... There are 2 bolts need undoing @19 in the last picture - i think....
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