How is BOOST measured in the 2.0d engine??

[alfadave11]

Originally Posted by ELO

So at idle the turbo actuator rod should be fully retracted in Max boost position, touching the stop screw?

it will be moved to default position ie it will be moved against spring tension
the position will be low boost

[alfadave11]

http://www.volvoforums.org.uk/showthread.php?t=170193

[ELO]

Update :-

Action taken -

1. Checked air filter for obstruction - clean
2. Check all charge pipes for splits or leaks - replaced 1 as precaution but P0299 still present
3. Make homemade boost leak tester and pressurize from turbo outlet up to end of charge pipes before throttle body, thus checking all charge pipes and intercooler for leaks - held 25 psi solid
4. Replace MAP sensor with new - no change
5. Clean MAF sensor - no change
5. Replace 3 TCVs (turbo control valves) and all vacuum hoses - no change (diagram of set up here http://www.volvoforums.org.uk/showthread.php?t=239019 )
6. Remove intake manifold and clean, check for cracks, renew gasket and o-rings - no change
8. Check for obstructions in exhaust as turbo can be resticted by blocked DPF or CAT (just loosened cat from turbo and drove so turbo could vent out easily) - no change
9. Checked turbo vane movement and operation by creating vacuum at actuator with a length of pipe and sucking with my mouth - worked fine
10. Cleaned vanes side of turbo to be on safe side - no change
11. Checked vacuum pump output - 27-28"Hg - fine
12. Checked vacuum at TCV output to turbo - 27"Hg - fine
13. Checked vacuum required to move actuator - 1-2"Hg to start and full actuation at 17"Hg - fine

Last thing in sequence to check -

14. Check operation of Turbo Actuator Position Sensor - remove and clean, then check voltage supply to sensor is good ( I was getting 5v between pin 1 and 2 and 4.3v between pin 1 and 3. Pin 1= +ve, pin 2= -ve, pin 3= signal).

This is where it gets odd! Since Ive taken this sensor out and checked it, exercised it, and cleaned it I've gone from one problem - P0299 under boost - up to P0238 - Turbocharger/Supercharger Boost Sensor 'A' Circuit High !!!

With the underboost fault the car was working fine, no limp mode or breaks in power delivery, but now when I hit 3000rpm under load, like climbing a hill or accelerating hard in 4th, where high boost is requested, the car is sensing over boost at 3000rpm and shutting off power delivery!!

I have ordered a new Actuator sensor and will fit it as soon as it arrives.

If this doesn't work its going back to have its remap erased or altered.

[Bungo]

Originally Posted by ELO

Yes. The car is driving fine. The tuner is suggesting that he could just delete the under boost code from the ECU as a solution but that is glossing over faults to me and doesn't sit right!

Could it be possible that if EGR hasn't been mapped out properly then ECU is expecting different MAP values and therefore throwing up under boost fault code??

Car is running fine then there are no faults to gloss over. You seem to have spent a lot of time and cash to try and delete a code that is causing no issues.
I would have taken back to who ever did the remap.
Some EGR blanks need a hole in them to avoid confusing the ECU

[alfadave11]

Originally Posted by ELO

Update :-

Action taken -

1. Checked air filter for obstruction - clean
2. Check all charge pipes for splits or leaks - replaced 1 as precaution but P0299 still present
3. Make homemade boost leak tester and pressurize from turbo outlet up to end of charge pipes before throttle body, thus checking all charge pipes and intercooler for leaks - held 25 psi solid
4. Replace MAP sensor with new - no change
5. Clean MAF sensor - no change
5. Replace 3 TCVs (turbo control valves) and all vacuum hoses - no change (diagram of set up here http://www.volvoforums.org.uk/showthread.php?t=239019 )
6. Remove intake manifold and clean, check for cracks, renew gasket and o-rings - no change
8. Check for obstructions in exhaust as turbo can be resticted by blocked DPF or CAT (just loosened cat from turbo and drove so turbo could vent out easily) - no change
9. Checked turbo vane movement and operation by creating vacuum at actuator with a length of pipe and sucking with my mouth - worked fine
10. Cleaned vanes side of turbo to be on safe side - no change
11. Checked vacuum pump output - 27-28"Hg - fine
12. Checked vacuum at TCV output to turbo - 27"Hg - fine
13. Checked vacuum required to move actuator - 1-2"Hg to start and full actuation at 17"Hg - fine

Last thing in sequence to check -

14. Check operation of Turbo Actuator Position Sensor - remove and clean, then check voltage supply to sensor is good ( I was getting 5v between pin 1 and 2 and 4.3v between pin 1 and 3. Pin 1= +ve, pin 2= -ve, pin 3= signal).

This is where it gets odd! Since Ive taken this sensor out and checked it, exercised it, and cleaned it I've gone from one problem - P0299 under boost - up to P0238 - Turbocharger/Supercharger Boost Sensor 'A' Circuit High !!!

With the underboost fault the car was working fine, no limp mode or breaks in power delivery, but now when I hit 3000rpm under load, like climbing a hill or accelerating hard in 4th, where high boost is requested, the car is sensing over boost at 3000rpm and shutting off power delivery!!

I have ordered a new Actuator sensor and will fit it as soon as it arrives.

If this doesn't work its going back to have its remap erased or altered.

removing actuator and refitting it has given you code p0238 which is consistent with variable vane issue ie sticking but more than likely out of phase ...that's why turbo technics garrett have a flow bench to set thus the adjustment rod
in your vida dice select parameters for desired and actual boost pressure and run a log of driving ...you will see actual and desired not being in sync
I still think your car problems are YOUR REMAP you shouldn't be going through all this when you didn't have issue before ....its called an action causes a reaction

[ELO]

I wouldn't dare play with the actuator rod set up as I'm aware its factory set and I wouldn't be able to set it right. I've merely removed the electronic actuator sensor and tested it, then refitted it. I suspect it's been giving out poor information. Since refitting it exactly as it was removed, but having cleaned and exercised it for smoother operation, the underboost fault code has gone and been replaced by over boost fault code! It's the last possible thing I can check, if the new one doesn't sort the problem then its back to the tuners with the confidence that I've checked everything I can before I suggest someone else is at fault.

[ELO]

Update:

After all that searching and testing I decided to return to the tuners and get the car's software map returned to stock. So far after two drives its not showing the P0299 or P0238 Boost fault codes.

She is back to how Volvo intended now.

Stick with stock is the moral of the story here!!

[alfadave11]

Originally Posted by ELO

Update:

After all that searching and testing I decided to return to the tuners and get the car's software map returned to stock. So far after two drives its not showing the P0299 or P0238 Boost fault codes.

She is back to how Volvo intended now.

Stick with stock is the moral of the story here!!

like ive stated before ....these are generic maps they download and call themselves tuners
moral of story is take it to professionals with a good reputation ..mappers charge in region of £400

[ELO]

I'm not 100% out of woods yet....http://www.volvoforums.org.uk/showth...29#post2016429

[nolanc30]

Originally Posted by ELO

Update:

After all that searching and testing I decided to return to the tuners and get the car's software map returned to stock. So far after two drives its not showing the P0299 or P0238 Boost fault codes.

She is back to how Volvo intended now.

Stick with stock is the moral of the story here!!

could you have been maxing out the stock map sensor? its only good for 2 bar and a mapped 2.0d would be about 2.5